Medical instruments for performing minimally-invasive procedures

ABSTRACT

Apparatus for performing a minimally-invasive procedure, the apparatus comprising: a shaft having a distal end, a proximal end and a longitudinal axis extending between the distal end and the proximal end, wherein the shaft comprises a flexible portion and an articulating portion, wherein the flexible portion extends distally from the handle assembly and the articulating portion extends distally from the flexible portion, and further wherein the articulating portion is configured to articulate relative to the flexible portion; a handle assembly attached to the proximal end of the shaft; and an end effector attached to the distal end of the shaft; wherein a plurality of articulation cables extends from the handle assembly to the articulating portion, such that when tension is applied to at least one of the plurality of articulation cables, the articulating portion bends relative to the flexible portion of the shaft; wherein the plurality of articulation cables are mounted to the handle assembly such that moving the handle assembly to angle the handle assembly relative to the longitudinal axis of the shaft applies tension to at least one of the plurality of articulation cables, whereby to articulate the articulating portion of the shaft relative to the flexible portion of the shaft.

REFERENCE TO PENDING PRIOR PATENT APPLICATIONS

This patent application:

(1) is a continuation-in-part of pending prior U.S. patent application Ser. No. 16/846,695, filed Apr. 13, 2020 by Lumendi Ltd. and Jonathan O'Keefe et al. for MEDICAL INSTRUMENTS FOR PERFORMING MINIMALLY-INVASIVE PROCEDURES (Attorney's Docket No. LUMENDI-051114 CON), which patent application is a continuation of prior U.S. patent application Ser. No. 15/298,605, filed Oct. 20, 2016 by Lumendi Ltd. and Jonathan O'Keefe et al. for MEDICAL INSTRUMENTS FOR PERFORMING MINIMALLY-INVASIVE PROCEDURES (Attorney's Docket No. LUMENDI-051114), which patent application claims benefit of (i) prior U.S. Provisional Patent Application Ser. No. 62/244,026, filed Oct. 20, 2015 by Lumendi Ltd. and Jonathan O'Keefe et al. for MEDICAL INSTRUMENTS FOR PERFORMING MINIMALLY-INVASIVE PROCEDURES (Attorney's Docket No. LUMENDI-5 PROV); and (ii) prior U.S. Provisional Patent Application Ser. No. 62/400,759, filed Sep. 28, 2016 by Lumendi Ltd. and Jonathan O'Keefe et al. for MEDICAL INSTRUMENTS FOR PERFORMING MINIMALLY-INVASIVE PROCEDURES (Attorney's Docket No. LUMENDI-1114 PROV); and

(2) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 63/153,819, filed Feb. 25, 2021 by Lumendi Ltd. and Jonathan O'Keefe et al. for MEDICAL INSTRUMENTS FOR PERFORMING MINIMALLY-INVASIVE PROCEDURES (Attorney's Docket No. LUMENDI-41 PROV).

The five (5) above-identified patent applications are hereby incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to medical instruments in general, and more particularly to medical instruments for performing minimally-invasive procedures.

BACKGROUND OF THE INVENTION

Minimally-invasive medical procedures have become commonplace. In a typical minimally-invasive procedure, access to an internal site is effected through one or more small portals (e.g., a natural body orifice, a small incision in the skin, etc.). A scope (e.g., a colonoscope, an arthroscope, an endoscope, etc.) is inserted through a portal so as to provide visualization of the internal site, and then one or more medical instruments are inserted, either through the same portal (e.g., via an internal channel in the scope) or through another portal, so that the medical instruments can be used to carry out a procedure at the internal site under the visualization provided by the scope.

In many cases the internal site may be difficult to reach due to anatomical constraints, equipment limitations, etc. By way of example but not limitation, in many situations it may be desirable for a medical instrument to be advanced to the internal site through an internal channel of a scope, or for a medical instrument to be advanced to the internal site alongside the scope, and then bent (e.g., along a short radius) so as to enter the visual field of the scope, so that the desired procedure is carried out under the visualization provided by the scope. And in many cases, the path along which the medical instrument needs to be advanced may be tortuous (e.g., endoluminally within the colon). In this situation, it is necessary for the medical instrument to be highly flexible, capable of articulating with a range of different motions, and configured for precise control, while being operated (e.g., along a tortuous path) from only the handle end (i.e., the proximal end) of the medical instrument. In practice, this is extremely difficult to achieve.

The present invention is intended to provide a novel medical instrument capable of such function.

SUMMARY OF THE INVENTION

The present invention comprises a novel medical instrument for performing minimally-invasive procedures. The novel medical instrument is highly flexible, capable of articulating with a range of different motions, and configured for precise control, while being operated (e.g., along a tortuous path) from only the handle end of the medical instrument.

The novel medical instrument generally comprises a handle and a shaft extending distally from the handle. The shaft generally comprises an elongated, flexible proximal portion and a distal articulating portion which is mounted to the distal end of the flexible proximal portion. An end effector is mounted to the distal end of the distal articulating portion. The end effector may take many different forms (e.g., graspers, injection needles, scissors, hot snares, monopolar probes, hemostasis clips, bipolar forceps, suction tubes, single-fire or multi-fire closure devices such as staplers and tackers, dissector forceps, retrieval baskets, monopolar scissors, light sources, cameras, etc.). For clarity of illustration, the end effector is shown in the figures as a grasper. The handle may take any one of many different forms (e.g., a pistol grip, a shaft grip, etc.). For clarity of illustration, the handle is shown in the figures as a pistol grip.

In accordance with the present invention, the flexible proximal portion of the shaft is configured to be a highly flexible element capable of extending a significant length (e.g., 95 cm-140 cm) along a tortuous path, the distal articulating portion of the shaft is configured to be capable of universal articulation relative to the distal end of the flexible proximal portion of the shaft, and the end effector is configured to be selectively rotated relative to the distal end of the distal articulating portion and may be selectively actuated, with all functions able to be carried out by a single hand of a user via the handle. In one preferred form of the invention, substantially the entire shaft of the medical instrument is flexible, with the portion of the shaft proximal to a transition point (i.e., the flexible proximal portion) being passively flexible (e.g., able to follow a tortuous path), and the portion of the shaft distal to the transition point (i.e., the distal articulating portion) being actively flexible (e.g., able to be universally articulated to a desired configuration).

As will hereinafter be described in further detail, the novel medical instrument is capable of at least the following motions:

Motion 1—longitudinal movement of the end effector by longitudinal movement of the handle (sometimes hereinafter referred to as a “longitudinal motion function”);

Motion 2—rotational movement of the end effector by rotational movement of the handle (sometimes hereinafter referred to as a “torquing motion function”);

Motion 3—articulating movement of the end effector relative to the handle by articulating the distal articulating portion of the shaft relative to the distal end of the flexible proximal portion of the shaft (sometimes hereinafter referred to as a “universal articulation function”);

Motion 4—rotational movement of the end effector relative to the distal end of the distal articulating portion of the shaft by rotating the end effector relative to the shaft (sometimes hereinafter referred to as a “roticulation function”); and

Motion 5—actuation of the end effector, e.g., selectively moving elements of the end effector relative to one another so as to carry out a medical procedure, e.g., opening and closing the jaws of a grasper-type end effector (sometimes hereinafter referred to as a “jaw open/close function”).

In one preferred form of the present invention, there is provided apparatus for performing a minimally-invasive procedure, the apparatus comprising:

a tool comprising:

-   -   a shaft having a distal end and a proximal end;     -   a handle attached to the proximal end of the shaft; and     -   an end effector attached to the distal end of the shaft;     -   wherein the shaft comprises a flexible portion extending         distally from the proximal end of the shaft, and an articulating         portion extending proximally from the distal end of the shaft,         and wherein the articulating portion comprises a flexible spine;     -   wherein a plurality of articulation cables extend through the         shaft from the handle to the flexible spine, each of the         plurality of articulation cables having an articulation cable         housing disposed about the articulation cable such that when         tension is applied to at least one of the plurality of         articulation cables, the flexible spine bends, with the         articulation cable housings providing a counterforce to the         flexible spine;     -   wherein a rotatable element extends through the shaft from the         handle to the end effector, such that when the rotatable element         is rotated, the end effector rotates; and     -   wherein an actuation element extends through the shaft from the         handle to the end effector, such that when the actuation element         is moved, the end effector is actuated.

In another preferred form of the present invention, there is provided a method for performing a minimally-invasive procedure, the method comprising:

obtaining apparatus for performing a minimally-invasive procedure, the apparatus comprising:

-   -   a tool comprising:         -   a shaft having a distal end and a proximal end;         -   a handle attached to the proximal end of the shaft; and         -   an end effector attached to the distal end of the shaft;         -   wherein the shaft comprises a flexible portion extending             distally from the proximal end of the shaft, and an             articulating portion extending proximally from the distal             end of the shaft, and wherein the articulating portion             comprises a flexible spine;         -   wherein a plurality of articulation cables extend through             the shaft from the handle to the flexible spine, each of the             plurality of articulation cables having an articulation             cable housing disposed about the articulation cable such             that when tension is applied to at least one of the             plurality of articulation cables, the flexible spine bends,             with the articulation cable housings providing a             counterforce to the flexible spine;         -   wherein a rotatable element extends through the shaft from             the handle to the end effector, such that when the rotatable             element is rotated, the end effector rotates; and         -   wherein an actuation element extends through the shaft from             the handle to the end effector, such that when the actuation             element is moved, the end effector is actuated; and

using the apparatus to perform a minimally-invasive procedure.

In another preferred form of the present invention, there is provided apparatus for performing a minimally-invasive procedure, the apparatus comprising:

a tool comprising:

-   -   a shaft having a distal end and a proximal end;     -   a handle attached to the proximal end of the shaft; and     -   an end effector attached to the distal end of the shaft;     -   wherein the shaft comprises a flexible portion extending         distally from the proximal end of the shaft, and an articulating         portion extending proximally from the distal end of the shaft,         and wherein the articulating portion comprises a flexible spine;     -   wherein a plurality of articulation cables extend through the         shaft from the handle to the flexible spine, such that when         tension is applied to at least one of the plurality of         articulation cables, the flexible spine bends;     -   wherein a rotatable element extends through the shaft from the         handle to the end effector, such that when the rotatable element         is rotated, the end effector rotates, wherein the rotatable         element comprises a hollow tubular structure extending distally         from the handle, the hollow tubular structure being formed out         of a plurality of filars which are wound and swaged together,         and further wherein the rotatable element further comprises a         laser-cut hypotube secured to the hollow tubular structure, such         that when the hollow tubular structure is rotated, the laser-cut         hypotube is also rotated; and wherein an actuation element         extends through the shaft from the handle to the end effector,         such that when the actuation element is moved, the end effector         is actuated.

In another preferred form of the present invention, there is provided a method for performing a minimally-invasive procedure, the method comprising:

obtaining apparatus for performing a minimally-invasive procedure, the apparatus comprising:

-   -   a tool comprising:         -   a shaft having a distal end and a proximal end;         -   a handle attached to the proximal end of the shaft; and         -   an end effector attached to the distal end of the shaft;         -   wherein the shaft comprises a flexible portion extending             distally from the proximal end of the shaft, and an             articulating portion extending proximally from the distal             end of the shaft, and wherein the articulating portion             comprises a flexible spine;         -   wherein a plurality of articulation cables extend through             the shaft from the handle to the flexible spine, such that             when tension is applied to at least one of the plurality of             articulation cables, the flexible spine bends;         -   wherein a rotatable element extends through the shaft from             the handle to the end effector, such that when the rotatable             element is rotated, the end effector rotates, wherein the             rotatable element comprises a hollow tubular structure             extending distally from the handle, the hollow tubular             structure being formed out of a plurality of filars which             are wound and swaged together, and further wherein the             rotatable element further comprises a laser-cut hypotube             secured to the hollow tubular structure, such that when the             hollow tubular structure is rotated, the laser-cut hypotube             is also rotated; and         -   wherein an actuation element extends through the shaft from             the handle to the end effector, such that when the actuation             element is moved, the end effector is actuated; and

using the apparatus to perform a minimally-invasive procedure.

In another preferred form of the present invention, there is provided apparatus for performing a minimally-invasive procedure, the apparatus comprising:

a tool comprising:

-   -   a shaft having a distal end and a proximal end;     -   a handle attached to the proximal end of the shaft; and     -   an end effector attached to the distal end of the shaft;     -   wherein the shaft comprises a flexible portion extending         distally from the proximal end of the shaft, and an articulating         portion extending proximally from the distal end of the shaft,         and wherein the articulating portion comprises a flexible spine;     -   wherein a plurality of articulation cables extend through the         shaft from the handle to the flexible spine, such that when         tension is applied to at least one of the plurality of         articulation cables, the flexible spine bends;     -   wherein a rotatable element extends through the shaft from the         handle to the end effector, such that when the rotatable element         is rotated, the end effector rotates;     -   wherein an actuation element extends through the shaft from the         handle to the end effector, such that when the actuation element         is moved, the end effector is actuated; and     -   wherein the flexible portion of the shaft comprises an outer         coil secured to the flexible spine, a rigid tube configured to         rotate relative to the handle, and an outer covering secured to         the rigid tube and the flexible spine, such that rotation of the         rigid tube causes rotation of the outer covering which causes         rotation of the flexible spine.

In another preferred form of the present invention, there is provided a method for performing a minimally-invasive procedure, the method comprising:

obtaining apparatus for performing a minimally-invasive procedure, the apparatus comprising:

-   -   a tool comprising:         -   a shaft having a distal end and a proximal end;         -   a handle attached to the proximal end of the shaft; and         -   an end effector attached to the distal end of the shaft;         -   wherein the shaft comprises a flexible portion extending             distally from the proximal end of the shaft, and an             articulating portion extending proximally from the distal             end of the shaft, and wherein the articulating portion             comprises a flexible spine;         -   wherein a plurality of articulation cables extend through             the shaft from the handle to the flexible spine, such that             when tension is applied to at least one of the plurality of             articulation cables, the flexible spine bends;         -   wherein a rotatable element extends through the shaft from             the handle to the end effector, such that when the rotatable             element is rotated, the end effector rotates;         -   wherein an actuation element extends through the shaft from             the handle to the end effector, such that when the actuation             element is moved, the end effector is actuated; and         -   wherein the flexible portion of the shaft comprises an outer             coil secured to the flexible spine, a rigid tube configured             to rotate relative to the handle, and an outer covering             secured to the rigid tube and the flexible spine, such that             rotation of the rigid tube causes rotation of the outer             covering which causes rotation of the flexible spine; and

using the apparatus to perform a minimally-invasive procedure.

In another preferred form of the present invention, there is provided apparatus for performing a minimally-invasive procedure, the apparatus comprising:

a tool comprising:

-   -   a shaft having a distal end and a proximal end;     -   a handle attached to the proximal end of the shaft; and     -   an end effector attached to the distal end of the shaft;     -   wherein the shaft comprises a flexible portion extending         distally from the proximal end of the shaft, and an articulating         portion extending proximally from the distal end of the shaft,         and wherein the articulating portion comprises a flexible spine;     -   wherein a plurality of articulation cables extend through the         shaft from the handle to the flexible spine, such that when         tension is applied to at least one of the plurality of         articulation cables, the flexible spine bends;     -   wherein a rotatable element extends through the shaft from the         handle to the end effector, such that when the rotatable element         is rotated, the end effector rotates;     -   wherein an actuation element extends through the shaft from the         handle to the end effector, such that when the actuation element         is moved, the end effector is actuated; and     -   wherein the proximal end of the shaft further comprises a rigid         portion, and wherein the apparatus further comprises a tool         support mounted to a patient support, the tool support         comprising an opening for receiving the rigid portion.

In another preferred form of the present invention, there is provided a method for performing a minimally-invasive procedure, the method comprising:

obtaining apparatus for performing a minimally-invasive procedure, the apparatus comprising:

-   -   a tool comprising:         -   a shaft having a distal end and a proximal end;         -   a handle attached to the proximal end of the shaft; and         -   an end effector attached to the distal end of the shaft;         -   wherein the shaft comprises a flexible portion extending             distally from the proximal end of the shaft, and an             articulating portion extending proximally from the distal             end of the shaft, and wherein the articulating portion             comprises a flexible spine;         -   wherein a plurality of articulation cables extend through             the shaft from the handle to the flexible spine, such that             when tension is applied to at least one of the plurality of             articulation cables, the flexible spine bends;         -   wherein a rotatable element extends through the shaft from             the handle to the end effector, such that when the rotatable             element is rotated, the end effector rotates;         -   wherein an actuation element extends through the shaft from             the handle to the end effector, such that when the actuation             element is moved, the end effector is actuated; and         -   wherein the proximal end of the shaft further comprises a             rigid portion, and wherein the apparatus further comprises a             tool support mounted to a patient support, the tool support             comprising an opening for receiving the rigid portion; and

using the apparatus to perform a minimally-invasive procedure.

In another preferred form of the present invention, there is provided apparatus for performing a minimally-invasive procedure, the apparatus comprising:

a tool comprising:

-   -   a shaft having a distal end and a proximal end;     -   a handle attached to the proximal end of the shaft; and     -   an end effector attached to the distal end of the shaft;     -   wherein the shaft comprises a flexible portion extending         distally from the proximal end of the shaft, and an articulating         portion extending proximally from the distal end of the shaft,         and wherein the articulating portion comprises a flexible spine;     -   wherein a plurality of articulation cables extend through the         shaft from the handle to the flexible spine, such that when         tension is applied to at least one of the plurality of         articulation cables, the flexible spine bends;     -   wherein a rotatable element extends through the shaft from the         handle to the end effector, such that when the rotatable element         is rotated, the end effector rotates; and     -   wherein an actuation element extends through the shaft from the         handle to the end effector, such that when the actuation element         is moved, the end effector is actuated;     -   the shaft being configured such that when the articulating         portion has been articulated, rotation of the rotatable element         occurs without the build-up of spring energy within the shaft.

In another preferred form of the present invention, there is provided a method for performing a minimally-invasive procedure, the method comprising:

obtaining apparatus for performing a minimally-invasive procedure, the apparatus comprising:

-   -   a tool comprising:         -   a shaft having a distal end and a proximal end;         -   a handle attached to the proximal end of the shaft; and         -   an end effector attached to the distal end of the shaft;         -   wherein the shaft comprises a flexible portion extending             distally from the proximal end of the shaft, and an             articulating portion extending proximally from the distal             end of the shaft, and wherein the articulating portion             comprises a flexible spine;         -   wherein a plurality of articulation cables extend through             the shaft from the handle to the flexible spine, such that             when tension is applied to at least one of the plurality of             articulation cables, the flexible spine bends;         -   wherein a rotatable element extends through the shaft from             the handle to the end effector, such that when the rotatable             element is rotated, the end effector rotates; and         -   wherein an actuation element extends through the shaft from             the handle to the end effector, such that when the actuation             element is moved, the end effector is actuated;         -   the shaft being configured such that when the articulating             portion has been articulated, rotation of the rotatable             element occurs without the build-up of spring energy within             the shaft; and

using the apparatus to perform a minimally-invasive procedure.

In another preferred form of the present invention, there is provided apparatus for performing a minimally-invasive procedure, the apparatus comprising:

a tool comprising:

-   -   a shaft having a distal end and a proximal end;     -   a handle attached to the proximal end of the shaft; and     -   an end effector attached to the distal end of the shaft;     -   wherein the shaft comprises a flexible portion extending         distally from the proximal end of the shaft, and an articulating         portion extending proximally from the distal end of the shaft,         and wherein the articulating portion comprises a flexible spine;     -   wherein a plurality of articulation cables extend through the         shaft from the handle to the flexible spine, such that when         tension is applied to at least one of the plurality of         articulation cables, the flexible spine bends;     -   wherein a rotatable element extends through the shaft from the         handle to the end effector, such that when the rotatable element         is rotated, the end effector rotates; and     -   wherein an actuation element extends through the shaft from the         handle to the end effector, such that when the actuation element         is moved, the end effector is actuated.

In another preferred form of the present invention, there is provided a method for performing a minimally-invasive procedure, the method comprising:

obtaining apparatus for performing a minimally-invasive procedure, the apparatus comprising:

-   -   a tool comprising:         -   a shaft having a distal end and a proximal end;         -   a handle attached to the proximal end of the shaft; and         -   an end effector attached to the distal end of the shaft;         -   wherein the shaft comprises a flexible portion extending             distally from the proximal end of the shaft, and an             articulating portion extending proximally from the distal             end of the shaft, and wherein the articulating portion             comprises a flexible spine;         -   wherein a plurality of articulation cables extend through             the shaft from the handle to the flexible spine, such that             when tension is applied to at least one of the plurality of             articulation cables, the flexible spine bends;         -   wherein a rotatable element extends through the shaft from             the handle to the end effector, such that when the rotatable             element is rotated, the end effector rotates; and         -   wherein an actuation element extends through the shaft from             the handle to the end effector, such that when the actuation             element is moved, the end effector is actuated; and

using the apparatus to perform a minimally-invasive procedure.

In one preferred form of the present invention, there is provided apparatus for performing a minimally-invasive procedure, the apparatus comprising:

a shaft having a distal end and a proximal end;

a handle attached to the proximal end of the shaft; and

an end effector attached to the distal end of the shaft;

wherein the shaft comprises a flexible portion, a first articulating portion and a second articulating portion, wherein the flexible portion extends distally from the handle, the first articulating portion extends distally from the flexible portion, and the second articulating portion extends distally from the first articulating portion;

wherein at least one articulation cable extends from the handle to the first articulating portion, such that when tension is applied to the at least one articulation cable, the first articulating portion deflects;

wherein a plurality of articulation cables extend from the handle to the second articulating portion, such that when tension is applied to at least one of the plurality of articulation cables, the second articulating portion deflects.

In another preferred form of the present invention, there is provided a method for performing a minimally-invasive procedure, the method comprising:

providing apparatus for performing a minimally-invasive procedure, the apparatus comprising:

-   -   a shaft having a distal end and a proximal end;     -   a handle attached to the proximal end of the shaft; and     -   an end effector attached to the distal end of the shaft;     -   wherein the shaft comprises a flexible portion, a first         articulating portion and a second articulating portion, wherein         the flexible portion extends distally from the handle, the first         articulating portion extends distally from the flexible portion,         and the second articulating portion extends distally from the         first articulating portion;     -   wherein at least one articulation cable extends from the handle         to the first articulating portion, such that when tension is         applied to the at least one articulation cable, the first         articulating portion deflects;     -   wherein a plurality of articulation cables extend from the         handle to the second articulating portion, such that when         tension is applied to at least one of the plurality of         articulation cables, the second articulating portion deflects;         and

using the apparatus to perform a minimally-invasive procedure.

In another form of the present invention, there is provided a new and improved handle for enabling the novel medical instrument to perform certain motions.

In another preferred form of the present invention, there is provided apparatus for performing a minimally-invasive procedure, the apparatus comprising:

a shaft having a distal end, a proximal end and a longitudinal axis extending between the distal end and the proximal end, wherein the shaft comprises a flexible portion and an articulating portion, wherein the flexible portion extends distally from the handle assembly and the articulating portion extends distally from the flexible portion, and further wherein the articulating portion is configured to articulate relative to the flexible portion;

a handle assembly attached to the proximal end of the shaft; and

an end effector attached to the distal end of the shaft;

wherein a plurality of articulation cables extends from the handle assembly to the articulating portion, such that when tension is applied to at least one of the plurality of articulation cables, the articulating portion bends relative to the flexible portion of the shaft;

wherein the plurality of articulation cables are mounted to the handle assembly such that moving the handle assembly to angle the handle assembly relative to the longitudinal axis of the shaft applies tension to at least one of the plurality of articulation cables, whereby to articulate the articulating portion of the shaft relative to the flexible portion of the shaft.

In another preferred form of the present invention, there is provided a method for performing a minimally-invasive procedure, the method comprising:

providing apparatus for performing the minimally-invasive procedure, the apparatus comprising:

-   -   a shaft having a distal end, a proximal end and a longitudinal         axis extending between the distal end and the proximal end,         wherein the shaft comprises a flexible portion and an         articulating portion, wherein the flexible portion extends         distally from the handle assembly and the articulating portion         extends distally from the flexible portion, and further wherein         the articulating portion is configured to articulate relative to         the flexible portion;     -   a handle assembly attached to the proximal end of the shaft; and     -   an end effector attached to the distal end of the shaft;     -   wherein a plurality of articulation cables extends from the         handle assembly to the articulating portion, such that when         tension is applied to at least one of the plurality of         articulation cables, the articulating portion bends relative to         the flexible portion of the shaft;     -   wherein the plurality of articulation cables are mounted to the         handle assembly such that moving the handle assembly to angle         the handle assembly relative to the longitudinal axis of the         shaft applies tension to at least one of the plurality of         articulation cables, whereby to articulate the articulating         portion of the shaft relative to the flexible portion of the         shaft; and

using the apparatus to perform the minimally-invasive procedure.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the preferred embodiments of the invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts, and further wherein:

FIG. 1 is a schematic view showing a novel medical instrument formed in accordance with the present invention;

FIG. 1A is a schematic view showing the handle and proximal end of the shaft of the novel medical instrument shown in FIG. 1;

FIG. 1B is a schematic view showing the distal end of the shaft and the end effector of the novel medical instrument shown in FIG. 1;

FIGS. 2-23 are schematic views showing further details of the shaft and the end effector of the novel medical instrument shown in FIG. 1;

FIGS. 24-46B are schematic views showing further details of the handle and the proximal end of the shaft of the novel medical instrument shown in FIG. 1;

FIGS. 47-55 are schematic views showing a novel tool support which may be used in conjunction with the novel medical instrument shown in FIG. 1;

FIGS. 56-58F are schematic views showing another novel medical instrument formed in accordance with the present invention;

FIGS. 59-62 are schematic views showing another form of end effector for the novel medical instrument of the present invention;

FIGS. 63-66 are schematic views showing another novel medical instrument formed in accordance with the present invention;

FIGS. 67-72 are schematic views showing another novel medical instrument formed in accordance with the present invention;

FIGS. 73 and 74 are schematic views showing another novel medical instrument formed in accordance with the present invention;

FIGS. 75 and 76 are schematic views showing another novel medical instrument formed in accordance with the present invention;

FIGS. 77-80 are schematic views showing another novel medical instrument formed in accordance with the present invention;

FIGS. 81-83, 83A and 84-87 are schematic views showing another novel medical instrument formed in accordance with the present invention;

FIG. 88 is a schematic view showing an alternative handle formed in accordance with the present invention;

FIGS. 89 and 90 are schematic views showing further details of the handle of FIG. 88;

FIGS. 90A and 90B are schematic views illustrating how a crimp plate may be disposed within the handle of FIG. 88;

FIGS. 91 and 91A are schematic views of novel friction locks that can be used in the handle of FIG. 88;

FIGS. 92 and 93 are schematic views showing further details of the handle of FIG. 88; and

FIGS. 94-96 are schematic views showing modifications to the shaft and end effector of the novel medical instrument of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

1 The Novel Medical Instrument in General

The present invention comprises a novel medical instrument for performing minimally-invasive procedures. The novel medical instrument is highly flexible, capable of articulating with a range of different motions, and configured for precise control, while being operated (e.g., along a tortuous path) from only the handle end of the medical instrument.

Looking first at FIGS. 1, 1A, 1B and 2, there is shown a novel medical instrument 5 formed in accordance with the present invention. Novel medical instrument 5 generally comprises a handle 10 and a shaft 15 extending distally from handle 10. Shaft 15 generally comprises an elongated, flexible proximal portion 20 and a distal articulating portion 25 which is mounted to the distal end of flexible proximal portion 20. An end effector 30 is mounted to the distal end of distal articulating portion 25. End effector 30 may take many different forms (e.g., graspers, injection needles, scissors, hot snares, monopolar probes, hemostasis clips, bipolar forceps, suction tubes, single-fire or multi-fire closure devices such as staplers and tackers, dissector forceps, retrieval baskets, monopolar scissors, light sources, cameras, etc.). For clarity of illustration, end effector 30 is shown in the figures as a grasper. Handle 10 may take any one of many different forms (e.g., a pistol grip, a shaft grip, etc.). For clarity of illustration, handle 10 is shown in the figures as a pistol grip.

In accordance with the present invention, flexible proximal portion 20 of shaft 15 is configured to be a highly flexible element capable of extending a significant length (e.g., 95 cm-140 cm) along a tortuous path, distal articulating portion 25 of shaft 15 is configured to be capable of universal articulation relative to the distal end of flexible proximal portion 20 of shaft 15, and end effector 30 is configured to be selectively rotated relative to the distal end of distal articulating portion 25 and may be selectively actuated, with all functions able to be carried out by a single hand of a user via handle 10. In one preferred form of the invention, substantially the entire shaft 15 of medical instrument 5 is flexible, with the portion of shaft 15 proximal to a transition point 32 (i.e., flexible proximal portion 20) being passively flexible (e.g., able to follow a tortuous path), and the portion of shaft 15 distal to transition point 32 (i.e., distal articulating portion 25) being actively flexible (e.g., able to be universally articulated to a desired configuration).

As will hereinafter be described in further detail, novel medical instrument is capable of at least the following motions:

Motion 1—longitudinal movement of end effector 30 by longitudinal movement of handle 10 (sometimes referred to herein as a “longitudinal motion function”);

Motion 2—rotational movement of end effector 30 by rotational movement of handle 10 (sometimes referred to herein as a “torquing motion function”);

Motion 3—articulating movement of end effector 30 relative to handle 10 by articulating distal articulating portion 25 of shaft 15 relative to the distal end of flexible proximal portion 20 of shaft 15 (sometimes referred to herein as a “universal articulation function”);

Motion 4—rotational movement of end effector 30 relative to the distal end of distal articulating portion 25 of shaft 15 by rotating end effector 30 relative to shaft 15 (sometimes referred to herein as a “roticulation function”); and

Motion 5—actuation of end effector 30, e.g., selectively moving elements of end effector 30 relative to one another so as to carry out a medical procedure, e.g., opening and closing the jaws of a grasper-type end effector (sometimes referred to herein as a “jaw open/close function”).

2 Construction of Shaft 15

2.1 Flexible Proximal Portion 20

Looking now at FIGS. 1, 1A, 1B and 2-4, flexible proximal portion 20 of shaft 15 generally comprises an elongated flexible outer coil 35 (FIGS. 2 and 3) having a distal end 40, a proximal end 45 and a lumen 50 extending therebetween. Distal articulating portion 25 of shaft 15 is mounted to distal end 40 of outer coil via intervening elements (see below). Proximal end 45 of outer coil 35 is secured to a shaft adapter 55 which is, in turn, secured to handle 10 (see below).

Means for selectively articulating distal articulating portion 25 relative to the distal end of flexible proximal portion 20 (i.e., relative to distal end 40 of outer coil 35), means for selectively rotating end effector 30 relative to distal articulating portion 25, and means for selectively actuating end effector 30 extend through lumen 50 of outer coil 35, as will hereinafter be discussed in further detail.

In one preferred form of the invention, a rigid tube 60 (FIGS. 1A and 4) is provided at the proximal end of flexible proximal portion 20 (i.e., disposed about the proximal end 45 of outer coil 35 and secured to shaft adapter 55), whereby to provide a region of increased rigidity for mounting novel medical instrument 5 to a tool support (e.g., a table-mounted tool support) as will hereinafter be discussed in further detail. If desired, rigid tube 60 may comprise a fillet 65 (FIG. 4) at the distal end of rigid tube 60 which provides a smooth transition between the outer surface of rigid tube 60 and the outer surface of the portion of flexible proximal portion 20 located distal to rigid tube 60.

2.2 Distal Articulating Portion 25 in General

As discussed above, distal articulating portion 25 is configured to selectively articulate relative to the distal end of flexible proximal portion 20. To this end, and looking now at FIGS. 2 and 5, distal articulating portion 25 generally comprises a distal articulation link assembly 70, a proximal articulation link assembly 75 and a flex spine 80 extending between distal articulation link assembly 70 and proximal articulation link assembly 75. Proximal articulation link assembly 75 is configured to be mounted to the distal end of flexible proximal portion 20 of shaft 15 and to provide a counterforce surface to enable selective articulation of distal articulation link assembly 70 and flex spine 80, as will hereinafter be discussed in further detail.

2.2.1 Proximal Articulation Link Assembly 75

Looking now at FIGS. 2 and 6, proximal articulation link assembly 75 is disposed at the distal end 40 of outer coil 35 of flexible proximal portion 20. The distal end of proximal articulation link assembly 75 provides a counterforce surface to enable selective flexing of distal articulation link assembly 70 and flex spine 80 relative to the distal end of flexible proximal portion 20 of shaft 15 (i.e., in order to effect universal articulation of distal articulating portion 25).

More particularly, proximal articulation link assembly 75 (FIG. 6) comprises a body 85 having a pair of distally-extending fingers 90 which are configured to engage flex spine 80 (FIG. 5) as will hereinafter be discussed in further detail. A plurality of bores 95 (FIG. 6), disposed about a central bore 100 (FIG. 18), are formed in body 85 and sized to receive a plurality of articulation cables (see below). If desired, bores 95 may comprise counterbores (not shown) disposed at their proximal ends for receiving articulation cable housings as will hereinafter be discussed. Central bore 100 (FIG. 18) may comprise a counterbore 102 (FIGS. 6 and 18) disposed at its distal end for facilitating mounting of distal articulating link assembly 70 to body 85, as will hereinafter be discussed.

Body 85 of proximal articulation link assembly 75 bears against a plurality of articulation cable housings 235 (see below) which, in turn, bear against handle in order for proximal articulation link assembly 75 to provide a counterforce surface for selective flexing of distal articulating portion 25 of shaft 15, as will hereinafter be discussed. Note that outer coil 35 is secured to body 85 of proximal articulation link assembly 75, but provides substantially no counterforce to body 85—the counterforce to body 85 is provided by the articulation cable housings.

2.2.2 Distal Articulation Link Assembly 70

Looking now at FIGS. 2, 5 and 7, distal articulation link assembly 70 generally comprises a body 105 (FIG. 7) having a central opening 110 passing therethrough, and a short laser-cut hypotube 115 extending proximally therefrom. Short laser-cut hypotube 115 comprises a distal end 120, a proximal end 125 and a lumen 130 extending therebetween. Short laser-cut hypotube 115 is configured to be highly flexible, but with sufficient column strength, so as to permit selective articulation of body 105 relative to proximal articulation link assembly 75 when proximal end 125 of short laser-cut hypotube 115 bears against body 85 (FIG. 6) of proximal articulation link assembly 75 and an off-center proximal force is applied to body 105, as will hereinafter be discussed. Proximal end 125 of short laser-cut hypotube 115 is mounted to body 85 of proximal articulation link assembly 75 (e.g., via welding). Distal end 120 of short laser-cut hypotube 115 is mounted to body 105 (e.g., via welding), with lumen 130 of short laser-cut hypotube 115 being aligned with central opening 110 of body 105 when distal articulation link assembly 70 is in its relaxed (i.e., unbiased) condition. As a result of this construction, rotation of body 85 of proximal articulation link assembly 75 causes rotation of laser-cut hypotube 115, whereby to cause rotation of body 105 of distal articulation link assembly 70. Body 105 also comprises a pair of distal seats 135 (only one of which is shown in FIG. 7) for mounting one or more articulation cables to body 105, as will hereinafter be discussed in further detail. Body 105 also comprises two proximally-extending fingers 137 for mating with flex spine 80 (FIG. 5), as will hereinafter be discussed in further detail.

2.2.3 Flex Spine 80

Looking now at FIG. 5, flex spine 80 generally comprises a flexible body 140 having a distal end 141 and a proximal end 142. A plurality of axially-aligned openings 145, and a central bore 150, extend between distal end 141 and proximal end 142. Openings 145 are sized to each receive an articulation cable therein as will hereinafter be discussed. Central bore 150 is sized to receive short laser-cut hypotube 115 (FIG. 7) of distal articulation link assembly 70. Proximal end 142 of flex spine 80 comprises proximal seats 155 for seating the aforementioned distally-extending fingers 90 (FIG. 6) of proximal articulation link assembly 75, and distal end 141 of flex spine 80 comprises distal seats 160 for receiving the aforementioned proximally-extending fingers 137 (FIG. 7) of distal articulation link assembly 70. It will be appreciated that when flex spine 80 is mounted in this fashion, flex spine 80 is fixed against rotation relative to either distal articulation link assembly 70 or proximal articulation link assembly 75.

2.2.4 Rotatable Housing Assembly 165

Looking next at FIGS. 5 and 8-12, the distal end of distal articulating portion 25 comprises a rotatable housing assembly 165 (FIG. 9) for rotatably mounting end effector 30 to distal articulation link assembly 70, as will hereinafter be discussed.

More particularly, rotatable housing assembly 165 generally comprises a collar 170, a long laser-cut hypotube 180 having a distal end 185, a proximal end 190 and a lumen 195 extending therebetween. Rotatable housing assembly 165 also comprises a rotation connector 200 (FIGS. 9 and 10) having an opening 205 formed therein which is fixedly mounted to distal end 185 of long laser-cut hypotube 180 such that lumen 195 of long laser-cut hypotube 180 is aligned with opening 205 of rotation connector 200 when rotatable housing assembly 165 is in its relaxed (i.e., unbiased) condition, and such that long laser-cut hypotube 180 and rotation connector 200 can rotate as a unit. An end effector mount 210 (FIGS. 8, 9, 11 and 12), is mounted to rotation connector 200 such that end effector mount 210 rotates when rotation connector 200 rotates (i.e., when long laser-cut hypotube 180 rotates). End effector 30 is mounted to end effector mount 210 (see below). Rotation connector 200 and end effector mount 210 are rotatably mounted to body 105 of distal articulation link assembly 70 (FIGS. 5 and 7) via collar 170 (FIG. 5). More particularly, rotation connector 200 (FIG. 9) is rotatably mounted to collar 170 and is able to rotate relative to collar 170. End effector mount 210 is mounted to rotation connector 200 and engages a distal shoulder 215 (FIG. 10) of rotation connector 200. Collar 170 is fixedly mounted to body 105 of distal articulation link assembly 75 (FIG. 7). Thus, end effector mount 210 (FIG. 9) is fixedly mounted to rotation connector 200 which is in turn fixedly connected to long laser-cut hypotube 180, and the foregoing subassembly (end effector mount 170, rotation connector 200 and long laser-cut hypotube 180) is rotatably mounted to collar 170, with collar 170 being fixedly mounted to distal articulation link assembly 70 (FIG. 5), and with long laser-cut hypotube 180 extending through central bore 150 of flex spine 80 and through bore 100 (FIG. 18) of body 85 of proximal articulating link assembly 75.

2.3 End Effector 30

End effector 30 may take many different forms (e.g., graspers, injection needles, scissors, hot snares, monopolar probes, hemostasis clips, bipolar forceps, suction tubes, single-fire or multi-fire closure devices such as staplers and tackers, dissector forceps, retrieval baskets, monopolar scissors, light sources, cameras, etc.). For clarity of illustration, end effector 30 is shown in the figures as a grasper.

In one preferred form of the invention, and looking now at FIG. 8, end effector 30 is mounted to end effector mount 210. More particularly, in one preferred form of the invention, end effector 30 comprises a grasper having two opposed jaws 216, 217 which are pivotally mounted to end effector mount 210 via a pin 217A which passes through holes 217B in jaws 216, 217 and through holes 217C in end effector mount 210. A clevis 218 is mounted to jaws 216, 217 via a pin 218A disposed in slots 218B formed in the proximal portions of jaws 216, 217 such that reciprocal movement of a pull wire mounted to clevis 218 (see below) causes the opposing jaws 216, 217 of the grasper to open and close relative to one another, as will hereinafter be discussed.

2.4 Articulation Means in General

As discussed above, shaft 15 also comprises (i) means for selectively articulating distal articulating portion 25 (FIG. 2) relative to flexible proximal portion 20, (ii) means for selectively rotating rotatable housing assembly 165 (FIG. 9) relative to shaft 15, and hence for selectively rotating end effector 30 relative to shaft 15, and (iii) means for selectively actuating end effector 30 (FIG. 8). All of the foregoing means are actuated via handle 10, as will hereinafter be discussed.

More particularly, and looking now at FIGS. 13 and 14, shaft 15 generally comprises (i) four articulation cables 220 for selectively articulating distal articulating portion 25 relative to the distal end of flexible proximal portion 20, (ii) an HHS coil 225 (e.g., a hollow helical strand of the sort sold by Fort Wayne Metals of Fort Wayne, Ind.) for selectively rotating rotatable housing assembly 165 (FIG. 9) relative to shaft 15, and hence for selectively rotating end effector 30 relative to shaft 15, and (iii) a pull wire 230 for selectively actuating end effector 30.

2.4.1 Articulation Cables 220

Looking next at FIGS. 13-16, in a preferred form of the invention, four articulation cables 220 run from handle 10 to distal seats 135 (FIGS. 15 and 16) of distal articulation link assembly 70, with articulation cables 220 extending through bores 95 of body 85 (FIG. 6), through openings 145 of flex spine 80 (FIG. 5) to distal seats 135 of body 105 (FIG. 16). Articulation cables 220 are preferably each slidably disposed within an articulation cable housing 235 (FIG. 13). The distal ends 240 of articulation cable housings 235 are mounted to body 85 (FIG. 15) of proximal articulation link assembly 75 (i.e., via thread adjusters 330, as will hereinafter be discussed). Articulation cable housings 235 bear against body 85 of proximal articulation link assembly 75 and provide a counterforce to body 85 for articulation of distal articulating portion 25 of shaft 15 relative to flexible proximal portion 25 of shaft 15. Articulation cable housings 235 also separate articulation cables 220 from one another and from HHS coil 225, and help ensure smooth sliding movement of articulation cables 220 within flexible proximal portion 20 of shaft 15 (i.e., over the distance between handle 10 and proximal articulation link assembly 75, which may be substantial in length (e.g., 95 cm-140 cm) and follow a tortuous path when medical instrument 5 is disposed in a patient). If desired, in order to facilitate mounting the distal ends of articulation cable housings 235 to the body 85 (FIG. 15), the proximal end of each bore 95 may comprise a counterbore (not shown) sized to receive the distal end 240 of a given articulation cable housing 235.

Looking now at FIGS. 15 and 16, after articulation cables 220 pass distally through openings 145 (FIG. 5) in flex spine 80, articulation cables 220 are attached (e.g., via welding, crimping, etc.) to distal seats 135 of body 105 of distal articulation link assembly 70. By way of example but not limitation, two of the articulation cables 220 may be provided by a single length of cable, with that single length of cable having a tube 245 (FIG. 16) crimped thereto and with tube 245 being welded (or otherwise affixed) to a distal seat 135.

As a result of this construction, by selectively pulling proximally on a proximal end of an articulation cable 220, body 105 (FIG. 7) of distal articulation link assembly 70 can be articulated laterally, whereby to articulate distal articulating portion 25 of shaft 15. Furthermore, by providing at least three articulation cables 220, with the three or more articulation cables being positioned about the perimeter of body 105, substantially universal articulation of distal articulation link assembly 70 can be achieved, whereby to provide substantially universal articulation for distal articulating portion 25 of shaft 15.

2.4.2 HHS Coil 225

Looking next at FIGS. 13, 14 and 17, HHS coil 225 comprises a distal end 250 (FIG. 17), a proximal end 255 (FIG. 26) and a lumen 260 (FIG. 13) extending therebetween. In order to facilitate rotation of HHS coil 225 within shaft 15, HHS coil 225 is preferably disposed within a flexible, friction-reducing sleeve 267 (FIG. 13). More particularly, HHS coil 225 preferably comprises a plurality of filars which are wound and swaged together so as to together form a hollow tubular structure. By way of example but not limitation, HHS coil 225 may comprise a hollow helical strand of the sort sold by Fort Wayne Metals of Fort Wayne, Ind. In one preferred form of the present invention, HHS coil 225 comprises 10 filars which are wound and swaged together into a singular flexible structure. Distal end 250 (FIG. 17) of HHS coil 225 is mounted to long laser-cut hypotube 180 (FIG. 17) of rotatable housing assembly 165 (FIG. 9) via a sleeve (or crimp) 265 (FIG. 17), such that long laser-cut hypotube 180 (and hence end effector mount 210 carrying end effector 30) rotate when HHS coil 225 rotates. It will be appreciated that, as a result of this construction, the rotational disposition of end effector 30 can be adjusted by selectively rotating HHS coil 225, whereby to rotate long laser-cut hypotube 180 and hence end effector mount 210, to which end effector 30 is secured. Significantly, by using HHS coil 225 and long laser-cut hypotube 180 to transmit torque down shaft 15, any build-up of torqueing spring energy within the shaft is minimized, even when shaft 15 follows a tortuous path and distal articulating portion 25 has been articulated relative to the longitudinal axis of shaft 15.

2.4.3 Pull Wire 230

Looking next at FIGS. 13, 14, 18 and 19, pull wire 230 is provided for selectively actuating end effector 30. The distal end of pull wire 230 (FIG. 19) is secured to clevis 218 of end effector 30, with clevis 218 being slidably mounted to jaws 216, 217 of end effector 30, and with jaws 216, 217 being pinned to end effector mount 210, such that reciprocal movement of pull wire 230 causes the opposing jaws 216, 217 of end effector 30 to open and close relative to one another.

2.5 Further Details on the Construction of Shaft 15

When shaft 15 is fully assembled, and looking now at FIGS. 18-23, body 85 (FIG. 18) of proximal articulation link assembly 75 (FIG. 6) is mounted to distal end 40 (FIG. 2) of flexible outer coil 35, with distal ends 240 (FIG. 15) of articulation cable housings 235 being mounted to body 85 of proximal articulation link assembly 75, and with articulation cables 220 passing through bores 95 (FIG. 6) formed in body 85. Distal articulation link assembly 70 (FIG. 7) is mounted to proximal articulation link assembly 75 by mounting proximal end 125 of short laser-cut hypotube 115 in counterbore 102 (FIG. 6) of body 85. Flexible body 140 (FIG. 5) of flex spine 80 is “sandwiched” between body 105 (FIG. 7) of distal articulation link assembly 70 and body 85 (FIG. 6) of proximal link assembly 75, with distally-extending fingers 90 of body 85 being disposed in proximal seats 155 (FIG. 5) of flex spine 80 and with proximally-extending fingers 137 of body 105 being disposed in distal seats 160 of flex spine 80. Short laser-cut hypotube 115 (FIG. 7) of distal articulation link assembly 70 passes through central bore 150 (FIG. 5) of flexible body 140 of flex spine 80. When articulation cables 220 are pulled proximally, the distal end of short laser-cut hypotube 115 bears against body 85 of proximal articulation link assembly 75 (which, in turn, bears against articulation cable housings 235), whereby to selectively articulate distal articulating portion 25 of shaft 15.

Long laser-cut hypotube 180 (FIGS. 9, 10 and 17) of rotatable housing assembly 165 extends proximally through short laser-cut hypotube 115 (FIG. 18) such that the proximal end 190 (FIG. 17) of long laser-cut hypotube 180 passes through body 85 of proximal articulation link assembly 75 (i.e., by passing through counterbore 102 and central bore 100 of body 85) and is secured to HHS coil 225 (FIG. 17), e.g., via sleeve 265. Collar 170 (FIG. 18) of rotatable housing assembly 165 (FIG. 9) is mounted to body 105 of distal articulation link assembly 70 and covers distal seats 135 (and the portions of articulation cables 220 mounted thereto). Rotation connector 200 (FIGS. 9 and 10) is mounted to the distal end of long laser-cut hypotube 180. Rotation connector 200 is also mounted to end effector mount 210. End effector 30 is mounted to end effector mount 210. As a result of this construction, when HHS coil 225 is rotated, long laser-cut hypotube 180 is rotated and rotation connector 200 is rotated and end effector mount 210 is rotated, whereby to cause rotation of end effector 30.

Pull wire 230 (FIG. 18) extends distally through lumen 260 of HHS coil 225 (FIGS. 13 and 14) and distally through lumen 195 (FIG. 9) of long laser-cut hypotube 180, exiting rotation connector 200. The distal end of pull wire 230 is connected to end effector 30. As a result of this construction, reciprocal movement of a pull wire 230 causes the opposing jaws 216, 217 (FIG. 8) of the grasper to open and close relative to one another.

Flexible proximal portion 20 of shaft 15 is preferably covered with a protective sleeve or outer covering (e.g., Pebax®) 270 (FIGS. 18, 20 and 21), with the proximal end of protective sleeve or outer covering 270 being secured (e.g., bonded) to rigid tube 60 and with the distal end of protective sleeve or outer covering 270 being secured (e.g., bonded) to body 85 of proximal articulation link assembly 75, and distal articulating portion 25 of shaft 15 is preferably covered with a protective sleeve or outer covering 275 (FIGS. 18 and 22), with the proximal end of protective sleeve or outer covering 275 being secured to body 85 of proximal articulation link assembly 75 and with the distal end of protective sleeve or outer covering 275 extending up to and over the proximal portion of end effector 30, whereby to protect shaft 15 and permit easy insertion of shaft 15 into the body of a patient via a natural body orifice, a cannula, the lumen of another surgical instrument, etc.

The proximal end of shaft 15 is mounted to handle 10 (FIG. 1) such that articulation cables 220, HHS coil 225 and pull wire 230 may be selectively actuated using handle 10, as will hereinafter be discussed in further detail.

3 Handle 10 in General

Looking now at FIGS. 24-26, handle 10 generally comprises an internal cavity 280, an articulation control assembly 285 for selectively moving articulation cables 220 (and hence selectively articulating distal articulating portion 25 of shaft 15), a push rod lock assembly 290 for selectively locking articulation control assembly 285 in a desired position (and hence locking distal articulating portion 25 of shaft 15 in a selected position), a roticulation control assembly 295 for selectively rotating HHS coil 225 (and hence selectively rotating end effector 30), and a trigger assembly 300 for selectively actuating pull wire 230 (and hence selectively actuating end effector 30).

3.1 Articulation Control Assembly 285

Looking now at FIGS. 27-36, articulation control assembly 285 generally comprises a ball plate 305 (FIG. 28) fixedly mounted within internal cavity 280 of handle 10, a thumbstick ball assembly 310 configured to be selectively pivoted relative to ball plate 305, and a thumbstick 315 configured to be engaged by the thumb of a user.

Ball plate 305 comprises a plurality of threaded openings 320 (FIG. 28) and a center opening 325 for receiving pushrod lock assembly 290, as will hereinafter be discussed in further detail. Threaded openings 320 are configured to receive a plurality of threaded adjusters 330 (FIGS. 29 and 30) which are, in turn, mounted to the proximal ends (FIGS. 21 and 30) of each articulation cable housing 235. It will be appreciated that, as a result of this construction, the proximal ends of articulation cable housings 235 bear against ball plate 305 (which is, in turn, fixedly mounted to handle 10), such that articulation cable housings 235 can provide a counterforce to body 85 of proximal articulation link assembly 75 when articulation cables 220 are pulled proximally. Each threaded adjuster 330 comprises a central lumen passing therethrough, such that an articulation cable 220 (FIG. 30) may pass through the threaded adjuster (and hence, through threaded openings 320 of ball plate 305) to be mounted to thumbstick ball assembly 310, as will hereinafter be discussed. An enlargement 335 (FIG. 30) is formed on (or attached to) the proximal end of each articulation cable 220, whereby to facilitate mounting articulation cables 220 to thumbstick ball assembly 310. Ball plate 305 also comprises a proximally-facing concave recess 340 (FIG. 29) for providing clearance to thumbstick ball assembly 310 which is pivotally seated within a seat 342 disposed within internal cavity 280 of handle 10, as will hereinafter be discussed in further detail.

Thumbstick ball assembly 310 comprises a hemispherical distal ball 345 (FIG. 32) and a hemispherical proximal ball 350. Hemispherical distal ball 345 preferably has a maximum diameter (i.e., the diameter at its proximal end) which is greater than the maximum diameter of hemispherical distal ball 345 (i.e., the diameter at its distal end), whereby to provide a proximal circumferential seat 355 (FIG. 31) about the proximal end of hemispherical distal ball 345. A plurality of openings (or grooves) 360 (FIG. 31) are formed in the proximal circumferential seat 355 for receiving articulation cables 220 when enlargements 335 are seated on proximal circumferential seat 355, as will hereinafter be discussed. As a result of this construction, when the rounded distal end of hemispherical distal ball 345 is pivotally disposed within seat 342 in internal cavity 280 of handle 10 (FIG. 27) and spaced from ball plate 305 (FIG. 33), articulation cables 220 may be passed through openings (or grooves) 360 in proximal circumferential seat 355 as enlargements 335 seat on proximal circumferential seat 355. Hence, articulation cables 220 may be selectively moved by selectively pivoting hemispherical distal ball 345 within its seat 342 inside internal cavity 280 of handle 10 (i.e., by selectively pivoting thumbstick 315, as will hereinafter be discussed in further detail).

Thumbstick 315 comprises a threaded stem 362 (FIG. 33) and a thumb seat 363. The distal end of threaded stem 362 secures hemispherical proximal ball 350 to hemispherical distal ball 345. Thumb seat 363 is secured to the proximal end of threaded stem 362. As a result of this construction, thumbstick 315 can be used to selectively move hemispherical distal ball 345, whereby to selectively move articulation cables 220, whereby to selectively articulate distal articulating portion 25 of shaft 15 relative to flexible proximal portion 20 of shaft 15.

3.1.1 Push Rod Lock Assembly 290

Looking next at FIGS. 27, 28 and 33-36, pushrod lock assembly 290 generally comprises an actuation lever 365 (FIG. 33), a cam 370 mounted to actuation lever 365, and a pushrod lock assembly plate 375 having a pushrod 380 mounted thereto and extending proximally therefrom. Pushrod 380 is preferably disposed within a sleeve 385. In one preferred form of the invention, a spring 390 (FIG. 35) is disposed over sleeve 385 so as to bias pushrod lock assembly plate 375 distally away from ball plate 305 (FIG. 36). Pushrod 380 is slidably disposed in center opening 325 (FIG. 28) of ball plate 305 and extends proximally therefrom toward thumbstick ball assembly 310 (FIG. 33). Actuation lever 365 and cam 370 are rotatably mounted within cavity 280 of handle 10, with cam 370 contacting pushrod lock assembly plate 375 such that movement of actuation lever 365 cams pushrod lock assembly plate 375 (and hence pushrod 380) proximally against the power of spring 390, whereby to cause the free end of pushrod 380 to engage hemispherical distal ball 345, thereby locking thumbstick ball assembly 310 against movement. When actuation lever 365 is moved in a second, opposite direction, cam 370 is moved so as to allow pushrod lock assembly plate 375 (and hence pushrod 380) to move distally under the power of spring 390, away from hemispherical distal ball 345, whereby to allow free movement of thumbstick ball assembly 310. As a result, it will be appreciated that pushrod lock assembly 290 can be used to selectively lock thumbstick ball assembly 310 in a desired position, whereby to selectively lock distal articulating portion 25 of shaft 15 in a desired (e.g., articulated) configuration.

3.2 Roticulation Control Assembly 295

Looking next at FIGS. 37-41, roticulation control assembly 295 generally comprises a roticulation knob 395 (FIGS. 37 and 38) having a keyway 400 (FIG. 38) passing therethrough, and a roticulation key 405. Roticulation key 405 comprises a distal end 406, a proximal end 407 and a lumen 408 extending therebetween. HHS coil 225 is received within lumen 408 of roticulation key 405 and is secured to roticulation key 405 such that rotation of roticulation key 405 effects rotation of HHS coil 225, with the degree to which roticulation key 405 rotates corresponding to the degree to which HHS coil 225 rotates (and hence the degree to which end effector 30 rotates). By way of example but not limitation, if roticulation key 405 is rotated 180 degrees, then HHS coil 225 (and end effector 30) will be rotated 180 degrees. Significantly, reticulation control assembly 295 is configured to rotate end effector 30 along all of, or a portion of, the circumference of the distal end of distal articulating portion 25 of shaft 15 (i.e., 1 degree, 360 degrees or any degree in between). As noted above, HHS coil 225 is secured to long laser-cut hypotube 180, and long laser-cut hypotube 180 is secured to end effector mount 210, such that rotation of HHS coil 225 causes rotation of long laser-cut hypotube 180 which causes rotation of end effector mount 210 (and hence rotation of end effector 30). Distal end 406 of rotaticulation key 405 is received in keyway 400 of roticulation knob 395 such that roticulation key 405 is engaged by roticulation knob 395 and rotates when roticulation knob 395 rotates. As a result of this construction, rotation of roticulation knob 395 causes rotation of roticulation key 405 which causes rotation of HHS coil 225 and hence rotation of end effector 30. In a preferred form of the invention, keyway 400 of roticulation knob 395 comprises a non-circular cross-sectional profile which matches the non-circular cross-sectional profile of distal end 406 of roticulation key 405.

Roticulation knob 395 is rotatably mounted within cavity 280 of handle 10 such that a portion of roticulation knob 395 protrudes out of handle 10 (FIG. 37), whereby to permit roticulation knob 395 to be selectively rotated by a user. Pull wire 230 (FIG. 40), which is disposed within HHS coil 225, extends through roticulation key 405 and is selectively actuated using trigger assembly 300 (FIG. 25), as will hereinafter be discussed.

Proximal end 407 of roticulation key 405 extends out of roticulation knob 395 (FIG. 39). In one preferred form of the present invention, proximal end 407 (FIG. 38) of roticulation key 405 comprises a plurality of teeth 409 for releasably engaging a ball nose spring plunger 410 (FIG. 41). Ball nose spring plunger 410 is mounted within cavity 280 of handle 10 such that ball nose spring plunger 410 releasably engages teeth 409 disposed on proximal end 407 of roticulation key 405. By virtue of the engagement between ball nose spring plunger 410 and roticulation key 405, roticulation key 405 (and hence HHS coil 225 which is mounted to roticulation key 405) are prevented from “spontaneously” rotating absent deliberate rotation of roticulation knob 395. Thus, ball nose spring plunger 410 prevents accumulated spring tension (e.g., spring tension which can build up when rotating HHS coil 225 using roticulation knob 395) from “unraveling” HHS coil 225 and thereby causing unintentional rotation of HHS coil 225 (and hence unintentional rotation of end effector 30).

3.3 Trigger Assembly 300

Looking next at FIGS. 42-46, 46A, 46B and 47, trigger assembly 300 generally comprises a trigger 415 pivotally mounted to handle 10, a sled 420 (FIG. 43) movably disposed within cavity 280 of handle 10, and one or more lever arms 425 which connect trigger 415 to sled 420 such that when trigger 415 is actuated (i.e., pulled), sled 420 moves proximally within cavity 280 of handle 10, whereby to move pull wire 230 proximally, whereby to actuate end effector 30, as will hereinafter be discussed in further detail.

More particularly, sled 420 comprises a cavity 430 (FIG. 45), a distal bushing 435 (FIG. 46) disposed within cavity 430, a proximal bushing 440 disposed within cavity 430, and a spring 445 disposed between distal bushing 435 and proximal bushing 440. An inner support tube 450 is secured to pull wire 230 (e.g., by a crimp sleeve 451 disposed at the proximal end of inner support tube 450). An outer support tube 452 is disposed over the distal portion of inner support tube 450, with inner support tube 450 able to slide freely within outer support tube 452. Outer support tube 452 also comprises an outer support tube collar 453 which is sized to be mounted within a seat 454 (FIG. 46B) formed in internal cavity 280 of handle 10. A spring 455 (FIG. 42) is disposed in the proximal end of handle 10 so as to bias sled 420 distally.

As a result of this construction, when sled 420 is moved proximally (i.e., by pulling trigger 415) against the power of spring 455 (FIG. 42), distal bushing 435 (FIG. 46) moves proximally, bearing against spring 445 which, in turn, bears against proximal bushing 440, which bears against crimp sleeve 451 and pulls pull wire 230 proximally. Thus, as sled 420 moves proximally, proximal bushing 440 and crimp sleeve 451 also move proximally, whereby to move pull wire 230 proximally and thereby actuate end effector 30. It should be appreciated, however, that inasmuch as sled 420 is not mounted directly to pull wire 230, proximal bushing 440 and spring 445 act as a force limiter, with spring 445 yielding when the force on pull wire 230 exceeds a given level, whereby to cease applying a proximal force to pull wire 230. Put another way, if the force applied to move sled 420 proximally exceeds the force biasing proximal bushing 440 away from distal bushing 435 (i.e., the biasing force provided by spring 445), spring 445 will compress, thereby allowing proximal bushing 440 and crimp sleeve 451 (and hence inner support tube 450 and pull wire 230) to remain stationary as sled 420 moves proximally. In this way trigger 415 can be pulled through a “full stroke” without the danger of breaking pull wire 230.

It should also be appreciated that since spring 455 biases sled 420 distally, and since crimp sleeve 451 is engaged by a shoulder 456 when sled 420 moves proximally, sled 420 will return to its distal position within handle 10 and pull wire 230 will be moved distally.

4 Exemplary Method of Use

In an exemplary use of novel medical instrument 5 in a minimally-invasive procedure, the profile of end effector 30 is reduced (e.g., where end effector 30 comprises a grasper, the jaws of the grasper are closed); shaft 15 is straightened; handle 10 is longitudinally advanced so as to longitudinally advance the distal end of medical instrument 5 through a portal and into the body (e.g., along a tortuous path); handle 10 is longitudinally advanced and/or rotated, and/or distal articulating portion 25 of shaft 15 is bent and/or end effector 30 is roticulated, so that end effector 30 appropriately addresses the target tissue at the internal site; end effector 30 is used to perform the desired procedure (e.g., where end effector 30 comprises a surgical grasper the jaws of the grasper are opened and closed to grasp tissue) at the internal site; and the distal end of medical instrument 5 is withdrawn from the body, e.g., handle 10 is longitudinally withdrawn through the portal (during which the handle may also be rotated, and/or distal articulating portion 25 of shaft 15 is unbent and/or the end effector roticulated as necessary), so that the end effector is withdrawn from the body.

It will be appreciated that novel medical instrument 5 is capable of at least the following motions:

Motion 1—longitudinal movement of end effector 30 by longitudinal movement of handle 10 (sometimes referred to herein as a “longitudinal motion function”);

Motion 2—rotational movement of end effector 30 by rotational movement of handle 10 (sometimes referred to herein as a “torquing motion function”);

Motion 3—articulating movement of end effector 30 relative to handle 10 by articulating distal articulating portion 25 of shaft 15 relative to the distal end of flexible proximal portion 20 of shaft 15 (sometimes referred to herein as a “universal articulation function”);

Motion 4—rotational movement of end effector 30 relative to the distal end of distal articulating portion 25 of shaft 15 by rotating end effector 30 relative to shaft 15 (sometimes referred to herein as a “roticulation function”); and

Motion 5—actuation of end effector 30, e.g., selectively moving elements of end effector 30 relative to one another so as to carry out a medical procedure, e.g., opening and closing the jaws of a grasper-type end effector (sometimes referred to herein as a “jaw open/close function”).

It will be appreciated by those skilled in the art that, if desired, the medical instrument may be modified so as to provide less (or more) than the five aforementioned motions, e.g., the roticulation function may be eliminated, an additional rotational function such as selective rotation of shaft 15 may be added, etc.

5 Novel Tool Support

Looking next at FIGS. 47-49, there is shown a novel tool support 460 which may be used to support medical instrument 5. Tool support 460 generally comprises a clamp 465 for mounting tool support 460 to a surgical table 466, an adjustable base 470 for mounting one or more medical instrument(s) 5 to tool support 460, and an adjustable arm 475 (FIG. 48) for adjustably mounting base 470 to clamp 465. One or more instrument adapters 480 (FIG. 49) are mounted to base 470, whereby to permit mounting of one or more medical instrument(s) 5 to tool support 460 (i.e., by providing a support for handle 10 and/or rigid tube 60 at the proximal end of shaft 15), as will hereinafter be discussed in further detail. One or more tool channels 485, configured for passing shaft 15 into a patient (or into the working lumen of another medical instrument), are mounted to the one or more instrument adapters 480, as will hereinafter be discussed in further detail.

More particularly, and still looking at FIGS. 47-50, clamp 465 is configured to be mounted to a stable object (e.g., to surgical table 466) in order to permit a surgeon to manipulate tool support 460 (and hence the one or more medical instruments 5 mounted thereto) relative to the patient and/or relative to other surgical instruments, as will hereinafter be discussed.

Adjustable arm 475 preferably comprises one or more segments 490 (FIG. 49) which are adjustably mounted to one another, and to clamp 465 and to base 470, whereby to permit the surgeon to precisely adjust the disposition of base 470 relative to the patient (and/or relative to another surgical instrument).

Looking now at FIGS. 49 and 50, instrument adapters 480 each comprise a mount 495 and a tube 500. Mount 495 is pivotally mounted to base 470 (FIG. 49). Tube 500 has a lumen 505 sized to receive the proximal end of shaft 15 of medical instrument 5 (i.e., rigid tube 60 located at the proximal end of shaft 15). If desired, lumen 505 may comprise a septum 515 for fluidically sealing tube 500 (and hence fluidically sealing tool chamber 485), and/or tube 500 may comprise an end cap 520 for fluidically sealing tube 500 (and hence, for fluidically sealing tool chamber 485).

Looking now at FIGS. 51-55, there are shown some exemplary configurations for tool support 460. It should be appreciated that base 470 of tool support 460 may comprise a plurality of pivots and/or arms, may be shaped in the form of an arc, and/or may comprise other geometries, etc., in order to accommodate the needs and/or preferences of the surgeon.

6 Medical Instrument 5 with Rotatable Shaft 15

As discussed above, novel medical instrument 5 comprises a shaft 15 having a flexible proximal portion 20, a distal articulating portion 25 which can be selectively articulated relative to the distal end of flexible proximal portion 20, and an end effector 30 which can be selectively rotated relative to the distal end of distal articulating portion 25. With this construction, longitudinal movement of handle 10 can be used to move shaft 15 distally and proximally, whereby to move end effector 30 distally and proximally; rotational movement of handle 10 can be used to rotate shaft 15, whereby to rotate end effector 30; articulation control assembly 285 (FIG. 25) can be used to articulate distal articulating portion 25 of shaft 15, whereby to redirect end effector 30; roticulation control assembly 295 (FIG. 25) can be used to rotate end effector 30; and trigger assembly 300 (FIG. 25) can be used to actuate end effector 30. With the foregoing construction, flexible proximal portion 20 rotates as a unit with handle 10.

However, it has been recognized that it may be desirable to be able to rotate flexible proximal portion 20 of shaft 15 independently of handle 10. To this end, and looking now at FIGS. 56-58, a novel rotatable shaft adapter mechanism 525 may be provided between shaft 15 and handle 10, whereby to allow shaft 15 (i.e., both flexible proximal portion 20 and distal articulating portion 25) to be selectively rotated relative to handle 10.

More particularly, rotatable shaft adapter mechanism 525 is mounted to the proximal end of shaft 15 (i.e., mounted to the proximal end of flexible proximal portion 20) and connects shaft 15 to handle 10. It should be appreciated that, in this form of the invention, rotatable shaft adapter mechanism 525 replaces the aforementioned shaft adapter 55 (where the aforementioned shaft adapter 55 was fixedly secured to handle 10 and fixedly secured to the proximal end of outer coil 35, and where rigid tube 60 was fixedly secured to shaft adapter 55). More particularly, in this form of the invention, shaft 15 is rotatably mounted to the distal end of handle 10 and selectively locked/unlocked from rotation via rotatable shaft adapter mechanism 525, as will hereinafter be discussed in further detail.

Still looking now at FIGS. 56-58, in this form of the invention, rigid tube 60 of shaft 15 comprises a flange 530 disposed around the proximalmost end of rigid tube 60. Flange 530 is received within a corresponding groove 535 formed in the distal end of handle 10 (i.e., formed within cavity 280 of handle 10 near the distalmost end of handle 10), whereby to rotatably mount rigid tube 60 of shaft 15 to handle 10. In this form of the invention, the proximal end of outer coil 35 is fixedly secured to rigid tube 60 (and the distal end of outer coil 35 is secured to body 85 of proximal articulation link assembly 75). The outer circumference of the distalmost end of handle 10 comprises a plurality of keyways 540 (FIG. 57) which are sized to receive a plurality of projections 542 formed on rotatable shaft adapter mechanism 525, as will hereinafter be discussed in further detail. Note that, if desired, the locations of keyways 540 and projections 542 may be reversed from the foregoing, i.e., keyways 540 may be formed on rotatable shaft adapter mechanism 525 and projections 542 may be formed on the distalmost end of handle 10.

Rotatable shaft adapter mechanism 525 generally comprises a shaft rotation knob 545 having a lumen 550 extending therethrough. Lumen 550 comprises a distal end 555, a proximal end 560 and an annular shoulder 565 disposed therebetween. A spring 570 is disposed within distal end 555 of lumen 550, extending between annular shoulder 565 and the proximal end 575 of a retaining cap 580 (FIGS. 58, 58A, 58B, 58C and 58D) which is mounted circumferentially about the outer perimeter of shaft 15, whereby to bias shaft rotation knob 545 proximally, so that projections 542 of shaft adapter mechanism 525 are received within keyways 540 of handle 10, whereby to lock shaft rotation knob 545 against rotation. More particularly, retaining cap 580 comprises a pair of flats 585 which key to corresponding flats 590 formed on the outer surface of rigid tube 60 of shaft 15. One or more spring fingers 591 engage a groove 592 on the outer surface of rigid tube 60, whereby to lock retaining cap 580 to rigid tube 60. Retaining cap 580 also comprises a plurality of key features 593 sized to be received in corresponding keyways 594 of shaft rotation knob 545. As a result of this construction, rotation knob 545 is able to slide longitudinally (distally or proximally) relative to rigid tube 60 of shaft 15, however, rotation knob 545 is locked against rotation relative to rigid tube 60 (and hence, relative to shaft 15). Therefore, rotation knob 545 can be moved longitudinally without causing longitudinal motion of rigid tube 60 and shaft 15, but rotation of rotation knob 545 will be transferred to rigid tube 60 (and to shaft 15 as will hereinafter be discussed).

Shaft rotation knob 545 is connected to rigid tube 60 of shaft 15 (e.g., via projections, a friction fit, etc.) so that shaft rotation knob 545 is longitudinally movable relative to rigid tube 60 but rotationally fixed to rigid tube 60.

In this form of the invention, the proximal end of protective sleeve or outer covering (e.g., Pebax®) 270 is secured (e.g., bonded) to rigid tube 60 and the distal end of protective sleeve or outer covering 270 is secured (e.g., bonded) to body 85 of proximal articulation link assembly 75. Significantly, protective sleeve or outer covering 270 is capable of transmitting torque between rigid tube 60 and body 85 of proximal articulation link assembly 75.

As a result of this construction, spring 570 normally biases shaft rotation knob 545 proximally, whereby to cause projections 542 to engage keyways 540 and lock shaft 15 against rotation relative to handle 10. However, when shaft rotation knob 545 is moved distally, against the power of spring 570, projections 542 disengage from keyways 540, thereby allowing shaft rotation knob 545 to be selectively rotated relative to handle 10, whereby to selectively rotate rigid tube 60 relative to handle 10, whereby to selectively rotate protective sleeve or outer covering 270 relative to handle 10, whereby to selectively rotate body 85 of proximal articulation link assembly 75, whereby to selectively rotate distal articulating portion 25 of shaft 15 relative to handle 10. When shaft 15 has been rotated to the desired position relative to handle 10, shaft rotation knob 545 is released and shaft rotation knob 545 moves proximally under the power of spring 570 such that projections 542 re-engage keyways 540, thereby locking shaft 15 against further rotation relative to handle 10.

Thus it will be seen that in this form of the invention, rigid tube 60 is rotatable relative to handle 10 but longitudinally fixed relative to handle 10; shaft rotation knob 545 is connected to rigid tube 60 such that shaft rotation knob 545 can be moved longitudinally relative to rigid tube 60 but not rotationally relative to rigid tube 60, such that shaft rotation knob 545 can be selectively locked to, or unlocked from, handle 10 so as to permit shaft rotation knob 545 to selectively rotate rigid tube 60; and protective sleeve or outer covering 270 transmits torque between rigid tube 60 and body 85 of proximal articulation link assembly 75, such that rotation of rigid tube 60 causes rotation of body 85 of proximal articulation link assembly 75, whereby to rotate distal articulating portion 25 of shaft 15 relative to handle 10.

It will be appreciated that unlimited rotation of rigid tube 60 and shaft 15 will cause articulation cables 220 and articulation cable housings 235 to wind on themselves; therefore, in one preferred form of the present invention, means are provided for limiting rotation of rigid tube 60 and shaft 15. More particularly, in one preferred form of the invention, and looking now at FIGS. 58E and 58F, rigid tube 60 of shaft 15 preferably comprises a groove 595 extending partially circumferentially about the outer surface of shaft 15. Groove 595 is disposed just distal to the proximal end of shaft 15 and extends partially, but not entirely, around the circumference of shaft 15. A corresponding boss 596 is formed on the distal end of handle 10 and received within groove 595. As a result of this construction, shaft 15 can be rotated only until boss 596 reaches one end of groove 595. In a preferred form of the present invention, groove 580 is sized so that shaft 15 can be rotated up to 350 degrees.

7 Additional Constructions

In the foregoing disclosure, there is described a novel medical instrument 5 comprising a handle, an elongated flexible shaft and an end effector disposed at the distal end of the shaft configured for performing a medical procedure. It should be appreciated that medical instrument 5 may be modified in a variety of ways in order to support different types of end effectors, to facilitate single-handed use of medical instrument 5, to enhance the functionality of medical instrument 5, etc.

7.1 Alternative End Effector

As discussed above, in a preferred form of the present invention, end effector 30 comprises a surgical grasper having two opposed jaws 216, 217 (FIG. 8).

In another preferred form of the present invention, and looking now at FIGS. 59-62, end effector 30 comprises scissors 600 having opposing blades 605, 610. Blades 605, 610 comprise sharp edges that contact one another in order to facilitate cutting (e.g., of tissue, suture, etc.) when blades 605, 610 are brought together (i.e., closed). In order to ensure clean cutting by blades 605, 610, it is desirable to maintain blades 605, 610 in tight contact with one another as blades 605, 610 are brought together (i.e., closed). To this end, a beveled washer 615 (FIGS. 61 and 62) is disposed between one of the blades 605, 610 and the inner wall of end effector mount 210. Beveled washer 615 is preferably disposed over the pin 217A which pivotally mounts blades 605, 610 to end effector mount 210. By mounting beveled washer 615 in this manner, blades 605, 610 are kept in tight engagement as they are brought together (i.e., closed), whereby to facilitate clean cutting (e.g., of tissue, of suture, etc.).

7.2 Finger Slide for Single-Handed Shaft Rotation

As discussed above, in one form of the present invention, shaft 15 is rotatably mounted to the distal end of handle 10 and can be selectively rotated using rotatable shaft adapter mechanism 525 (FIGS. 56-58 and 58A-58F). With this form of the invention, the proximal end of shaft 15 is rotationally mounted to the distal end of handle 10 (e.g., by means of the aforementioned flange 530 (FIG. 58) on rigid tube 60 being rotationally received within the aforementioned corresponding groove 535 formed in the distal end of handle 10), and rotatable shaft adapter mechanism 525 is moved distally (i.e., pushed distally by the user against the power of spring 570) in order to “unlock” shaft 15 (i.e., to allow shaft rotation knob 545, and hence shaft 15, to rotate). A user can then rotate shaft 15 as desired (i.e., by rotating rotatable shaft adapter mechanism 525, and hence rotating shaft 15). After the user has rotated shaft 15 as desired, shaft adapter mechanism 525 is released and automatically moves proximally (i.e., under the power of spring 570) so as to “lock” shaft 15 against further rotation. This action typically requires that the user use one hand to push rotatable shaft adapter mechanism 525 distally (and thereafter rotate shaft 15) while the user uses their other hand to keep handle 10 stationary.

However, it should be appreciated that it may also be desirable for a user to rotate shaft 15 using a single hand. To this end, in another form of the present invention, shaft 15 is kept stationary (e.g., via friction between the outer surface of shaft 15 and the interior of a tool channel (e.g., tool channel 485 (FIG. 48), the lumen of a tool channel provided in another medical instrument such as an endoscope, etc.), handle 10 is selectively rotationally de-coupled from shaft 15, and handle 10 is selectively rotated by a user to a desired rotational position using a single hand. Handle 10 is then rotationally re-coupled to shaft 15 and then rotated by the user (whereby to also rotate shaft 15).

More particularly, with this form of the invention, and looking now at FIGS. 63-66, a shaft rotation finger slide assembly 625 is provided in order to enable single-handed rotation of shaft 15, as will hereinafter be discussed in further detail. Shaft rotation finger slide assembly 625 generally comprises a finger slide mechanism 630 which is slidably disposed within handle 10, and a shaft collar 635 which is fixedly mounted to the proximal end of shaft 15 (e.g., fixedly mounted to rigid tube 60).

Finger slide mechanism 630 comprises a saddle 640 having a pair of projections 645 extending through corresponding slots (not shown) formed in the side wall of handle 10. A pair of finger slides 647 are secured to projections 645. A post 650 extends distally from saddle 640 and is configured to selectively lock shaft collar 635 against rotation, as will hereinafter be discussed in further detail. A spring 655 biases saddle 640 (and hence post 650) distally, such that post 650 engages shaft collar 635 when finger slide mechanism 630 is in its resting state, as will hereinafter be discussed in further detail.

Shaft collar 635 is fixedly mounted to the proximal end of shaft 15 (e.g., to rigid tube 60). Shaft collar 635 comprises a distal end 660, a proximal end 665 and a lumen 670 extending therebetween. A plurality of teeth 675 are disposed about the inside perimeter of lumen 670 at proximal end 665 of shaft collar 635, with teeth 675 being spaced such that post 650 of finger slide mechanism 630 can be received within the gap between a pair of adjacent teeth 675, whereby to lock shaft collar 635 (and hence shaft 15) against rotation, as will hereinafter be discussed in further detail.

When a user desires to rotate shaft 15, the user moves finger slides 647 proximally, whereby to move projections 645 proximally, whereby to move saddle 640 proximally against the power of spring 655. As this occurs, post 650 is also moved proximally, whereby to disengage post 650 from teeth 675 of shaft collar 635 (and thereby rotationally de-couple handle 10 from shaft 15). While holding projections 645 proximally, the user can then rotate handle 10 as desired relative to shaft 15. Shaft 15 does not rotate as handle 10 is rotated (i.e., shaft 15 is maintained stationary by virtue of friction between the outer surface of shaft 15 and the interior of the lumen that shaft 15 is disposed in, e.g., tool channel 485).

After the user has rotated handle 10 to the desired degree, the user releases finger slides 647, which allows projections 645 and saddle 640 (and hence post 650) to move distally under the power of spring 655, with post 650 moving distally into a space between a pair of teeth 675 of shaft collar 635, whereby to rotationally re-couple handle 10 to shaft collar 635 (and hence shaft 15). At this point, the user can rotate handle 10 as desired in order to rotate shaft 15. By way of example but not limitation, if a user desires to rotate shaft 15 clockwise 90 degrees, the user can rotationally de-couple shaft 15 from handle 10 in the manner discussed above, rotate handle 10 counterclockwise 90 degrees (e.g., rotate the grip of handle 10 from the “6 o'clock” position to the “3 o'clock” position), re-couple shaft 15 to handle 10 in the manner discussed above, and then rotate handle 10 (and hence shaft 15) clockwise 90 degrees (e.g., rotate the grip of handle 10 from the “3 o'clock” position to the “6 o'clock” position).

7.3 Single-Plane Articulation Mechanism

As discussed above, in one preferred form of the present invention, articulation control assembly 285 comprises thumbstick ball assembly 310, which is configured to selectively pull one or more of four articulation cables 220 proximally, whereby to allow selective universal articulation of distal articulating portion 25 of shaft 15 relative to flexible proximal portion 20 of shaft 15 via movement of thumbstick ball assembly 310.

However, it has been recognized that it is also sometimes desirable to provide a simplified articulation control assembly which may be used with only two articulation cables, e.g., to provide single-plane articulation of distal articulating portion 25 of shaft 15 relative to flexible proximal portion 20 of shaft 15. To that end, in one form of the present invention, and looking now at FIGS. 67-69, there is shown an articulation control assembly 680 which is similar to the articulation control assembly 285 discussed above, but which is configured to provide single-plane articulation, as will hereinafter be discussed in further detail.

More particularly, articulation control assembly 680 comprises a rocker 685 pivotally mounted within internal cavity 280 of handle 10. Rocker 685 may be pivotally mounted within internal cavity 280 via an appropriately-formed seat disposed within internal cavity 280 of handle 10 or by other means (e.g., a pivot pin). A thumb lever 690 is mounted to rocker 685 and extends proximally through a slot 695 formed in the housing of handle 10 (FIG. 69). A wedge-shaped thumb rest 700 is preferably mounted to the free end of thumb lever 690. Two articulation cables 220 (not shown) are mounted to rocker 685 (e.g., by mounting the proximal ends of articulation cables 220 within diametrically-opposed slots 705 formed on rocker 685).

As a result of this construction, a user can selectively articulate, in a single plane, distal articulating portion 25 of shaft 15 by selectively moving thumb lever 690, whereby to selectively pivot rocker 685 in a single plane, and thereby selectively pull one of the two articulation cables 220 which are mounted to rocker 685 proximally.

7.4 HHS Coil Comprising Compressive Outer Wrap

As discussed above, pull wire 230 is disposed within lumen 260 of HHS coil 225 and is able to slide freely relative to HHS coil 225 in order to selectively actuate end effector 30 (i.e., when a user pulls trigger 415 of handle 10, whereby to move pull wire 230 proximally).

It has been found that inasmuch as shaft 15 (and hence, HHS coil 225) can extend a substantial distance along a tortuous path (e.g., though the colon of a patient), HHS coil 225 can sometimes longitudinally compress (i.e., longitudinally shorten) while pull wire 230 does not longitudinally compress (i.e., longitudinally shorten). When this occurs, since HHS coil 225 provides the counterforce for pull wire 230, pull wire 230 needs to be moved a further distance proximally in order to actuate end effector 30. However, further proximal movement of pull wire 230 may not be possible if trigger 415 has reached the end of its “throw” (i.e., if trigger 415 cannot be pulled further).

In order to minimize longitudinal compression of HHS coil 225, and looking now at FIGS. 70-72, in one form of the present invention there is provided a flat wound coil 710 which is wound around HHS coil 225. Flat wound coil 710 is welded to distal end 250 of HHS coil 225 and is welded to proximal end 255 of HHS coil 225. Coil 710 rotates with HHS coil 225 and provides support to HHS coil 225, whereby to minimize longitudinal compression of HHS coil 225. As a result of this construction, HHS coil 225 does not compress longitudinally (i.e., HHS coil 225 does not shorten) when shaft 15 is disposed along a tortuous path.

7.5 Cover for End Effector Mount 210

As discussed above, end effector 30 may be pivotally mounted within end effector mount 210 via a pin 217A passing through the end effector and jaws 216, 217 of the grasper.

However, with certain end effectors, it is necessary to provide openings in the sides of end effector mount 210 so that the proximal ends of the elements of the end effector have room to move when the end effector is in certain configurations. By way of example but not limitation, and looking now at FIGS. 73 and 74, in one form of the present invention, end effector 30 comprises scissors. More particularly, in this form of the invention, end effector 30 comprises a first blade 715 having a distal end 720 and a proximal end 725, and a second blade 730 having a distal end 735 and a proximal end 740. First blade 715 and second blade 730 are pivotally mounted to one another and to end effector mount 210 via a pin 745. When first blade 715 and second blade 730 are opened (i.e., to receive tissue, suture, etc. that is to be cut), proximal end 725 of first blade 715, and proximal end 740 of second blade 730, project laterally out of end effector mount 210 (FIG. 73). It has been found that proximal ends 725, 740 can present a sharp surface which can damage surrounding equipment and/or the anatomy when end effector 30 is used in a surgical procedure, particularly when end effector 30 is rotated at a surgical site while blades 715, 730 are in their opened position. To eliminate this issue, a cover 750 may be provided which covers the proximal portion of end effector mount 210. As a result, the proximal ends 725, 740 of blades 715, 730 remain covered even when blades 715, 730 are in their open position, whereby to prevent damage to the anatomy or other surgical equipment. In one preferred form of the invention, cover 750 is formed out of an electrically-insulating material so that cover 750 also provides electrical insulation. This can be advantageous where end effector 30 comprises monopolar scissors, etc.

7.6 Enhanced Handle And Trigger Ergonomics

As discussed above, in one preferred form of the present invention, trigger 415 (FIG. 25) is pivotally mounted to handle 10 and may be selectively pulled by a user in order to selectively actuate end effector 30. For the purposes of illustration, trigger 415 is shown in FIG. 25 as a traditional “pistol type” trigger, and handle 10 is shown as comprising a traditional “pistol type” grip.

However, it has been found that it is sometimes desirable to provide additional stabilization elements on handle 10 (e.g., to facilitate single-handed use of medical instrument 5) and/or to provide a trigger having a longer throw (i.e., an increased arc of movement) for providing better leverage.

To these ends, and looking now at FIGS. 75 and 76, in one form of the invention, a handle 10 comprises a “pinky” stabilizer ring 755 for receiving the “pinky” finger of a user and a “shepard's hook”-type trigger 760 for providing greater leverage and superior ergonomics to a user. This construction facilitates a better single-handed grip of handle 10 by a user and also allows a user to easily move trigger 415 proximally or distally (e.g., to pull or push pull wire 230 in order to selectively close/open the jaws of a grasper, etc.)

7.7 Monopolar Electrical Current Delivery

In some circumstances it is desirable to be able to deliver monopolar electrical power to end effector 30. By way of example but not limitation, where end effector 30 comprises monopolar (“hot”) scissors, it is necessary to transmit electrical power from handle 10, along (or through) shaft 15, to end effector 30.

To that end, and looking now at FIGS. 77-80, in one preferred form of the present invention, there is provided an electrical connection port (e.g., a “banana jack”) 765 disposed on the proximal end of the grip of handle 10 for connection to an external power supply (not shown), and a wire 770 (FIG. 79) disposed within internal cavity 280 of handle 10 for routing electrical power from electrical connection port 765 to a flat conductive spring 775 disposed within handle 10 (FIG. 80). Flat conductive spring 775 contacts the plurality of teeth 409 disposed on roticulation key 405, whereby to make electrical contact with roticulation key 405 and hence HHS coil 225 and/or pull wire 230 via roticulation key 405. It should be appreciated that, with this form of the invention, ball nose spring plunger 410 is preferably omitted (i.e., it is replaced by flat conductive spring 775). In addition, with this form of the invention, roticulation key 405 (and teeth 409 of roticulation key 405) are formed out of an electrically-conductive material (e.g., metal), as is long laser-cut hypotube 180, rotation connector 200 and end effector mount 210. As a result, electrical power can pass from an external power supply (not shown) to electrical connection port 765, along wire 770 to flat conductive spring 775, from conductive spring 775 to roticulation key 405, and then to HHS coil 225 (and also to pull wire 230), along HHS coil 225 (and pull wire 230) through flexible proximal portion 20 of shaft 15, through sleeve (or crimp) 265 to long laser-cut hypotube 180, along long laser-cut hypotube 180 (and pull wire 230) through distal articulating portion 25 of shaft 15, to rotation connector 200 and end effector mount 210, and from end effector mount 210 to end effector 30. In this way, monopolar power can be supplied to end effector 30.

8 Medical Instrument 5 with an Additional Degree of Articulation

As discussed above, in a preferred form of the present invention, novel medical instrument 5 generally comprises a shaft 15 having a flexible proximal portion 20, a distal articulating portion 25 configured to be selectively articulated relative to the distal end of flexible proximal portion 20, and an end effector 30 configured to be selectively rotated relative to the distal end of distal articulating portion 25. With this form of the invention, longitudinal movement of handle 10 can be used to selectively move shaft 15 distally or proximally, whereby to move end effector 30 distally or proximally; rotational movement of handle 10 can be used to rotate shaft 15 (and hence, to also rotate end effector 30); articulation control assembly 285 (FIG. 25) can be used to selectively articulate distal articulating portion 25 of shaft 15 relative to flexible proximal portion 20 of shaft 15, whereby to permit control over the positioning of end effector 30; roticulation control assembly 295 (FIG. 25) can be used to selectively rotate end effector 30 relative to distal articulating portion 25 of shaft 15; and trigger assembly 300 (FIG. 25) can be used to selectively actuate end effector 30. It should be appreciated that, in this form of the invention, flexible proximal portion 20 of shaft 15 rotates as a unit together with handle 10.

As also discussed above, in another preferred form of the present invention, novel medical instrument 5 may further comprise a rotatable shaft adapter mechanism 525 actuated with a rotation knob 545 (FIGS. 56-58) which can be selectively rotated so as to allow shaft 15 (i.e., both flexible proximal portion and distal articulating portion 25) to be selectively rotated relative to handle 10.

However, it should also be appreciated that, in some circumstances, it may be desirable to add an additional degree of articulation to shaft 15 of novel medical instrument. By way of example but not limitation, when medical instrument 5 is passed along a sharp bend in the colon (or other anatomical structure), shaft 15 of medical instrument 5 is constrained by the anatomy and is forced to deflect along the outer curve of the bend in the colon (or other anatomical structure), thereby making it difficult for end effector 30 to be aligned with, and grasp tissue disposed along, the corresponding inner curve of the bend in the colon (or other anatomical structure). Thus there is a need for a medical instrument that permits a greater degree of articulation and hence greater options for addressing the anatomy with end effector 30.

To this end, and looking now at FIG. 81, in another preferred form of the present invention, novel medical instrument 5 further comprises an intermediate articulating portion 800 disposed between the distal end of flexible proximal portion 20 and the proximal end of distal articulating portion 25. Intermediate articulating portion 800 can be articulated in a single plane (e.g., in a manner analogous to the human “elbow” joint) in order to provide another degree of articulation to the distal articulating end portion of medical instrument 5, as will hereinafter be discussed in further detail. This additional degree of articulation is sometimes hereinafter referred to as a “gross articulation function”.

With the additional degree of articulation provided by the gross articulation function provided by intermediate articulating portion 800, novel medical instrument 5 is capable of at least the following motions:

Motion 1—longitudinal movement of end effector 30 by longitudinal movement of handle 10 (sometimes referred to herein as a “longitudinal motion function”);

Motion 2—rotational movement of end effector 30 by rotational movement of handle 10 (sometimes referred to herein as a “torquing motion function”);

Motion 3—articulating movement of end effector 30 relative to handle 10 by articulating distal articulating portion 25 of shaft 15 relative to the distal end of intermediate articulating portion 800 of shaft 15 (sometimes referred to herein as a “universal articulation function”);

Motion 4—rotational movement of end effector 30 relative to the distal end of distal articulating portion 25 of shaft 15 by rotating end effector 30 relative to shaft 15 (sometimes referred to herein as a “roticulation function”);

Motion 5—actuation of end effector 30, e.g., selectively moving elements of end effector 30 relative to one another so as to carry out a medical procedure, e.g., opening and closing the jaws of a grasper-type end effector (sometimes referred to herein as a “jaw open/close function”);

Motion 6—rotation of shaft 15 independently of handle 10, e.g., selectively rotating rotation knob 545 of rotatable shaft adapter mechanism 525 to allow shaft 15 (and hence flexible proximal portion 20, intermediate articulating portion 800 and distal articulating portion 25) to be selectively rotated relative to handle 10; and

Motion 7—articulating movement of distal articulating portion 25 and end effector 30 relative to flexible proximal portion 20 of shaft 15 by articulating intermediate articulating portion 800 of shaft 15 relative to the distal end of flexible proximal portion 20 of shaft 15 (sometimes referred to herein as a “gross articulation function”).

More particularly, and looking next at FIGS. 82, 83 and 83A, in this form of the invention, novel medical instrument 5 comprises (i) the four aforementioned articulation cables 220 for selectively articulating distal articulating portion 25 relative to the distal end of flexible proximal portion 20, (ii) the aforementioned hollow helical strand (HHS) coil 225 for selectively rotating rotatable housing assembly 165 (FIG. 9) relative to shaft 15, and hence for selectively rotating end effector 30 relative to shaft 15, (iii) the aforementioned pull wire 230 for selectively actuating end effector 30, and (iv) a gross articulation cable 805 for selectively articulating intermediate articulating portion 800 relative to the distal end of flexible proximal portion 20, as will hereinafter be discussed in further detail.

Still looking at FIGS. 82, 83 and 83A, intermediate articulating portion 800 generally comprises a flex spine 810 (e.g., a laser-cut hypotube) having a proximal end 815, a distal end 820, and a central cavity 825 disposed therebetween. Proximal end 815 of intermediate articulating portion 800 is mounted (e.g., welded, crimping, etc.) to distal end 40 of flexible outer coil 35, and distal end 820 of intermediate articulating portion 800 is mounted (e.g., welded, crimping, etc.) to proximal articulation link assembly 75.

Gross articulation cable 805 runs from distal end 820 of flex spine 810 to handle 10. The distal end of gross articulation cable 805 comprises a crimp (not shown), which is welded to the distal end of gross articulation cable 805, which is, in turn, mounted to (e.g. welded to) the inside surface of flex spine 810 proximate distal end 820 of flex spine 810. The proximal end of gross articulation cable 805 is attached to a control assembly within handle 10, as will be discussed in further detail below.

The portion of gross articulation cable 805 which extends between distal end 820 of flex spine 810 and proximal end 815 of flex spine 810 is slidably disposed within a gross articulation cable conduit 830 which is disposed within cavity 825 of flex spine 810. The portion of gross articulation cable 805 which extends from distal end 40 of flexible outer coil 35, through flexible proximal portion 20 and through shaft 15 to handle 10 is slidably disposed within an articulation cable housing 235. Gross articulation cable conduit 830 is welded to proximal end 815 of flex spine 810, and articulation cable housing 235 is welded to flexible outer coil 35 of shaft 15, but gross articulation cable conduit 830 is not connected to articulation cable housing 235.

Gross articulation cable conduit 830 and articulation cable housing 235 separate gross articulation cable 805 from articulation cables 220/articulation cable housings 235, and from HHS coil 225/torque liner 267, whereby to ensure smooth sliding movement of gross articulation cable 805 within intermediate articulating portion 800, flexible proximal portion 20 and shaft 15 (i.e., over the distance between distal end 820 of flex spine 810 and handle 10, which may be substantial in length (e.g., 95 cm-140 cm) and which often follows a tortuous path when medical instrument 5 is disposed in a patient).

Gross articulation cable conduit 830 is constructed so as to be more compressible than articulation cable housing 235 so as to ensure that flex spine 810 can deflect to a desired angle. In one preferred form of the invention, gross articulation cable conduit 830 comprises a coiled spring such that proximal movement of gross articulation cable 805 causes flex spine 810 to articulate relative to distal end 40 of flexible outer coil 35 while allowing gross articulation cable conduit 830 to compress along its longitudinal dimension.

As a result of this construction, by selectively moving gross articulation cable 805 proximally, flex spine 810 of intermediate articulating portion 800 can be selectively articulated laterally relative to distal end 40 of flexible outer coil 35, whereby to selectively articulate intermediate articulating portion 800 of shaft 15.

Significantly, inasmuch as only a single gross articulation cable 805 is provided, intermediate articulating portion 800 can only be articulated in a single plane. However, if desired, additional gross articulation cables 805 may be provided if articulation in additional planes is desired, as will be apparent to one skilled in the art in view of the present disclosure.

Looking next at FIGS. 81 and 84-87, a preferred mechanism for selectively moving gross articulation cable 805 is shown.

More particularly, as discussed above, handle 10 generally comprises an internal cavity 280, an articulation control assembly 285 for selectively moving articulation cables 220 (and hence selectively articulating distal articulating portion 25 of shaft 15), a push rod lock assembly 290 for selectively locking articulation control assembly 285 in a desired position (and hence locking distal articulating portion 25 of shaft 15 in a selected position), a roticulation control assembly 295 for selectively rotating HHS coil 225 (and hence selectively rotating end effector 30), a trigger assembly 300 for selectively actuating pull wire 230 (and hence selectively actuating end effector 30), and a rotatable shaft adapter mechanism 525 for selectively rotating shaft 15 (i.e., flexible proximal portion 20, intermediate articulating portion 800 and distal articulating portion 25) relative to handle 10.

In this form of the present invention, handle 10 is also provided with a gross articulation control assembly 835 for selectively moving gross articulation cable 805 proximally or distally (and hence selectively articulating flex spine 810 of intermediate articulating portion 800 of shaft 15 relative to flexible proximal portion 20 of shaft 15).

Gross articulation control assembly 835 generally comprises a spindle housing 840 fixedly mounted within internal cavity 280 of handle 10, a spindle 845 configured to be selectively rotated within spindle housing 840, and a knob 850 configured to be engaged by a user.

The proximal end of gross articulation cable 805 exits the proximal end of shaft 15, passes through a portion of internal cavity 280 of handle 10, and is mounted to spindle 845 (e.g., via a crimp welded to gross articulation cable 805 and to spindle 845, via welding directly to spindle 845, etc.). Cable housing 235 for gross articulation cable 805 preferably terminates at the proximal end of shaft 15, however, if desired, cable housing 235 for gross articulation cable 805 may extend into internal cavity 280 of handle 10 and terminate at the outer wall of spindle housing 840.

As a result of this construction, when knob 850 is rotated in a first direction, the proximal end of gross articulation cable 805 is pulled proximally, whereby to selectively articulate flex spine 810 of intermediate articulating portion 800 of shaft 15 from a straight configuration to an articulated configuration (relative to flexible proximal portion 20 of shaft 15), and when knob 850 is rotated in a second, opposite direction, the tension on the proximal end of gross articulation cable 805 is relaxed and allowed to move distally, whereby to enable flex spine 810 of intermediate articulating portion 800 of shaft to return to its straight, non-articulated configuration.

It should also be appreciated that, if desired, flex spine 810 of intermediate articulating portion 800 can be configured to automatically return to its straight (i.e., non-articulated) configuration when knob 850 is released by a user. By way of example but not limitation, flex spine 810 may be formed out of a resilient flexible material that is biased towards assuming a straight configuration. As a result of this construction, releasing knob 850 of gross articulation control assembly 835 permits gross articulation cable 805 to move distally (i.e., under the power of the biasing force provided by the resilient nature of flex spine 810), whereby to permit flex spine 810 to return to its straight (i.e., non-articulated) configuration. Alternatively and/or additionally, if desired, an additional gross articulation cable 805A (not shown) may be provided, wherein the distal end of the additional gross articulation cable 805A is mounted (e.g., diametrically opposed to gross articulation cable 805) to the inner surface of flex spine 810 proximate distal end 820 of flex spine 810, whereby to help facilitate returning flex spine 810 (and hence intermediate articulating portion 800) to its straight (i.e., non-articulated) configuration and/or articulating flex spine 810 in a second, opposite direction.

It is important to note that rotating knob 850 of gross articulation control assembly 835 so as to articulate flex spine 810 of intermediate articulating portion 800 typically requires the use of two hands (i.e., one hand to grip handle 10, and the other hand to rotate knob 850). However, it should be appreciated that, if desired, knob 850 could be replaced with a lever (not shown) or other actuation means, so as to enable one-handed articulation of flex spine 810 of intermediate articulating portion 800.

In an exemplary use of this form of novel medical instrument 5 in a minimally-invasive procedure, the profile of end effector 30 is first reduced (e.g., where end effector 30 comprises a grasper, the jaws of the grasper are closed);

shaft 15 is straightened; handle 10 is longitudinally advanced so as to longitudinally advance the distal end of medical instrument 5 through a portal and into the body (e.g., along a tortuous path); handle 10 is longitudinally advanced and/or rotated, and/or distal articulating portion 25 of shaft 15 is articulated, and/or intermediate articulating portion 800 is articulated, and/or end effector 30 is rotated so that end effector 30 appropriately addresses the target tissue at the internal site; end effector 30 is used to perform the desired procedure (e.g., where end effector 30 comprises a surgical grasper, the jaws of the grasper are opened and/or closed to grasp tissue and/or perform a surgical procedure) at the internal site; and the distal end of medical instrument 5 is withdrawn from the body, e.g., handle 10 is longitudinally withdrawn through the portal (during which the handle may also be rotated, and/or distal articulating portion 25 of shaft 15 is straightened (i.e., moved so as to assume its non-articulated configuration), and/or flex spine 810 of intermediate articulating portion 800 is straightened (i.e., moved so as to assume its non-articulated configuration) and/or end effector 30 is rotated and/or actuated (e.g., if necessary to reduce the profile of end effector 30), so that the end effector may be withdrawn from the body.

It will be appreciated by those skilled in the art that, if desired, the medical instrument may be modified so as to provide less (or more) than the seven aforementioned motions, e.g., the roticulation function may be eliminated, an additional rotational function such as selective rotation of shaft 15 may be added, etc.

9 Alternative Handle for Medical Instrument 5

As discussed above, and as shown in FIGS. 1-46B, in a preferred form of the present invention, novel medical instrument 5 generally comprises a shaft 15 having a flexible proximal portion 20, a distal articulating portion 25 configured to be selectively articulated relative to the distal end of flexible proximal portion 20, and an end effector 30 configured to be selectively rotated relative to the distal end of distal articulating portion 25. With this form of the invention, longitudinal movement of handle 10 can be used to selectively move shaft 15 distally or proximally (i.e., in a direction parallel to the longitudinal axis of shaft 15), whereby to move end effector 30 distally or proximally; rotational movement of handle 10 can be used to rotate shaft 15 (and hence, to also rotate end effector 30); articulation control assembly 285 (FIG. 25) can be used to selectively articulate distal articulating portion 25 of shaft 15 relative to flexible proximal portion 20 of shaft 15, whereby to permit control over the positioning of end effector 30; roticulation control assembly 295 (FIG. 25) can be used to selectively rotate end effector 30 relative to distal articulating portion 25 of shaft 15; and trigger assembly 300 (FIG. 25) can be used to selectively actuate end effector 30. It should be appreciated that, in this form of the invention, flexible proximal portion 20 of shaft 15 rotates as a unit together with handle 10.

As also discussed above, in another preferred form of the present invention, novel medical instrument 5 may further comprise a rotatable shaft adapter mechanism 525 actuated with a rotation knob 545 (FIGS. 56-58 and 58A-58F), which can be selectively rotated so as to allow shaft 15 (i.e., both flexible proximal portion 20 and distal articulating portion 25) to be selectively rotated relative to handle 10.

Furthermore, as shown in FIGS. 81-87 and as also discussed above, in another preferred form of the present invention, novel medical instrument 5 may additionally comprise an intermediate articulating portion 800 (disposed between the distal end of flexible proximal portion 20 and the proximal end of distal articulating portion 25) which can be selectively articulated in a single plane (e.g., in a manner analogous to the human “elbow” joint) in order to provide another degree of articulation to the distal articulating end portion of medical instrument 5. This additional degree of articulation is sometimes hereinafter referred to as a “gross articulation function”.

With the additional degree of articulation provided by the gross articulation function provided by intermediate articulating portion 800, novel medical instrument 5 is capable of at least the following motions:

Motion 1—longitudinal movement of end effector 30 by longitudinal movement of handle 10 (sometimes referred to herein as a “longitudinal motion function”);

Motion 2—rotational movement of end effector 30 by rotational movement of handle 10 (sometimes referred to herein as a “torquing motion function”);

Motion 3—articulating movement of end effector 30 relative to handle 10 by articulating distal articulating portion 25 of shaft 15 relative to the distal end of intermediate articulating portion 800 of shaft 15 (sometimes referred to herein as a “universal articulation function”);

Motion 4—rotational movement of end effector 30 relative to the distal end of distal articulating portion 25 of shaft 15 by rotating end effector 30 relative to shaft 15 (sometimes referred to herein as a “roticulation function”);

Motion 5—actuation of end effector 30, e.g., selectively moving elements of end effector 30 relative to one another so as to carry out a medical procedure, e.g., opening and closing the jaws of a grasper-type end effector (sometimes referred to herein as a “jaw open/close function”);

Motion 6—rotation of shaft 15 independently of handle 10, e.g., selectively rotating rotation knob 545 of rotatable shaft adapter mechanism 525 to allow shaft 15 (and hence flexible proximal portion 20, intermediate articulating portion 800 and distal articulating portion 25) to be selectively rotated relative to handle 10; and

Motion 7—articulating movement of distal articulating portion 25 (and hence end effector 30) relative to flexible proximal portion 20 of shaft 15 by articulating intermediate articulating portion 800 of shaft 15 relative to the distal end of flexible proximal portion 20 of shaft 15 (sometimes referred to herein as a “gross articulation function”).

In order to effect these motions, novel medical instrument 5 comprises a handle 10 comprising:

(i) an articulation control assembly 285 for selectively moving the four articulation cables 220 extending from the handle to the distal end of distal articulating portion 25 (and hence selectively articulating distal articulating portion 25 of shaft 15 relative to the distal end of flexible proximal portion 20);

(ii) a push rod lock assembly 290 for selectively locking articulation control assembly 285 in a desired position (and hence locking distal articulating portion 25 of shaft 15 in a selected position);

(iii) a roticulation control assembly 295 for selectively rotating the HHS coil 225 extending from the handle to end effector 30 (and hence selectively rotating end effector 30 relative to shaft 15);

(iv) a trigger assembly 300 for selectively actuating pull wire 230 (and hence selectively actuating end effector 30);

(v) a rotatable shaft adapter mechanism 525 for selectively rotating shaft (i.e., flexible proximal portion 20, intermediate articulating portion 800 and distal articulating portion 25) relative to handle 10; and

(vi) a gross articulation control assembly 835 for selectively moving gross articulation cable 805 proximally or distally (and hence selectively articulating flex spine 810 of intermediate articulating portion 800 of shaft 15 relative to flexible proximal portion 20 of shaft 15).

Looking now at FIGS. 88-93, an alternative handle 10A is provided for medical instrument 5. As will be discussed in further detail below, handle 10A is similar to handle 10 discussed above except that (i) thumb-activated articulation control assembly 285 of handle 10 has been replaced with a wrist-activated articulation control assembly 900, (ii) rotatable shaft mechanism 525 has been replaced with rotatable shaft mechanism 525A, and (iii) gross articulation control assembly 835 has been replaced with a gross articulation control assembly 1000.

9.1 Wrist-Activated Articulation Control Assembly 900

As shown in FIGS. 27-36 and 85, articulation control assembly 285 generally comprises a ball plate 305 (FIG. 28) fixedly mounted within internal cavity 280 of handle 10, a thumbstick ball assembly 310 configured to be selectively pivoted relative to a ball plate 305, and a thumbstick 315 configured to be engaged by the thumb of a user for pivoting thumbstick ball assembly 310 relative to ball plate 305. Articulation cables 220 are mounted to thumbstick ball assembly 310 so that movement of thumbstick 315 by the thumb of the user pulls one or more of four articulation cables 220 proximally, whereby to allow selective universal articulation of distal articulating portion 25 of shaft 15 relative to the distal end of flexible proximal portion 20.

In some circumstances, it may be desirable to articulate distal flexible portion 25 by moving the user's wrist (instead of by using the user's thumb to manipulate thumbstick 315). To this end, and looking now at FIGS. 88-93, a novel handle 10A for enabling distal flexible portion 25 to be articulated through movement of a user's wrist is provided. It will be appreciated that, in this form of the invention, handle 10A is generally similar to handle 10 shown in the embodiment of FIGS. 1-46B, and shaft 15 is generally similar to the shaft shown in the embodiment of FIGS. 81-87, however, articulation control assembly 285 and push rod lock assembly 290 of handle 10 are replaced by articulation control assembly 900 (FIG. 88).

Articulation control assembly 900 generally comprises a crimp plate 905 which is mounted within internal cavity 280 of handle 10A, and an articulation ball 910 fixed to the proximal end of shaft 15. See FIGS. 89 and 90. The four articulation cables 220 are mounted to crimp plate 905 (e.g., by mounting the proximal ends of articulation cables 220 within slots 915 formed on crimp plate 905), as will be discussed in further detail below, and articulation ball 910 is disposed within a socket 920 of handle 10A. As a result of this construction, rotating socket 920 of handle 10A (e.g., by moving the user's wrist) around articulation ball 910 will move crimp plate 905 (and hence one or more of the four articulation cables 220) distally and/or proximally, whereby to allow selective universal articulation of distal articulating portion 25 of shaft 15 relative to the distal end of flexible proximal portion 20, as will be discussed in further detail below.

More particularly, articulation ball 910 comprises a distal end 925 and a proximal end 930, with distal end 925 of articulation ball 910 being mounted to the proximal end of shaft 15 and proximal end 930 of articulation ball 910 comprising an adjuster plate 935. Adjuster plate 935 comprises four openings 940 for receiving the four articulation cables 220, one opening (not shown) for receiving gross articulation cable 805, and a center opening 942 for receiving HHS coil 225. Openings 940 are each configured to receive a threaded adjuster 945 which is, in turn, mounted to the proximal end of each of the articulation cable housings 235. It will be appreciated that, as a result of this construction, the proximal ends of articulation cable housings 235 bear against adjuster plate 935, such that articulation cable housings 235 can provide a counterforce to body 85 of proximal articulation link assembly 75 (FIG. 6) when articulation cables 220 are pulled proximally by the rotation of socket 920 of handle 10A around articulation ball 910. Each threaded adjuster 945 comprises a central lumen 950 passing therethrough, such that an articulation cable 220 may pass through threaded adjuster 945 (and hence, through openings 940 of adjuster plate 935) to be mounted to crimp plate 905, as will hereinafter be discussed. An enlargement 335 (FIG. 30) is formed on (or attached to) the proximal end of each articulation cable 220, whereby to facilitate mounting articulation cables 220 to crimp plate 905.

Crimp plate 905 comprises a distal portion 955 and a proximal portion 960. A plurality of grooves 965 are formed on distal portion 955 of crimp plate 905 and a plurality of slots 915 are formed on proximal portion 960 of crimp plate 905. Grooves 965 and slots 915 together form a passageway for receiving articulation cables 220, with enlargements 335 being seated in slots 915 of crimp plate 905. In a preferred form of the invention, distal portion 955 of crimp plate 905 is disposed proximal to, and spaced from, adjuster plate 935 of articulation ball 910.

As a result of this construction, articulation cables 220 may be passed from the distal end of distal articulating portion 25, through shaft 15, through openings 940 in adjuster plate 935 and into grooves 965 in crimp plate 905, with enlargements 335 being fixed in slots 915 of proximal portion 960 of crimp plate 905. Hence, when socket 920 is rotated around articulation ball 910 (e.g., by moving the user's wrist), crimp plate 905 (and hence one or more of the four articulation cables 220) will be moved proximally, whereby to allow selective universal articulation of distal articulating portion 25 of shaft 15 relative to the distal end of flexible proximal portion 20.

It will be appreciated that the disposition of crimp plate 905 proximal to the proximal end 930 of articulation ball 910 provides a significant advantage over a design in which the crimp plate is disposed within, or in any way distal to, the proximal end of the articulation ball. By way of example but not limitation, and looking now at FIGS. 90A and 90B, there are shown two schematic views illustrating two different manners in which crimp plate 905 may be disposed relative to articulation ball 910, whereby to illustrate the comparative advantage of disposing crimp plate 905 proximal to proximal end 930 of articulation ball 910.

More particularly, FIG. 90A shows a configuration in which crimp plate 905 is disposed intermediate distal end 925 and proximal end 930 of articulation ball 910 (i.e., a “centrally-disposed” disposition of crimp plate 905). In the configuration of FIG. 90A, R2 refers to the moment arm of a crimp plate 905 that is centrally disposed within articulation ball 910 having a radius R1. It will be appreciated that since R2 is necessarily a shorter length than R1, the moment arm (i.e., the force exerted on articulation cables 220 mounted to a centrally-disposed crimp plate 905 as the articulation ball 910 rotates within socket 920) is necessarily constrained by the radius R1 of articulation ball 910.

By contrast, and looking now at FIG. 90B, in a configuration such as that of the present invention (i.e., a configuration in which crimp plate 905 is disposed proximal to proximal end 930 of articulation ball 910), the moment arm R3 is unconstrained by the radius R1 of articulation ball 910, and hence R3 can be significantly longer than the moment arm of the configuration shown in FIG. 90A.

As a result of this construction, the configuration shown in FIG. 90B confers a significant benefit. Specifically, due to the longer moment arm resulting from the proximal disposition of crimp plate 905 relative to articulation ball 910, the surgeon is able to achieve a greater degree of control over the selective articulation of distal articulating portion 25 of shaft 15 with smaller movements of the wrist (i.e., smaller movements to cause articulation ball 910 to rotate relative to socket 920 of handle 10A).

In a preferred form of the present invention a retaining ring 966 is disposed over articulation ball 910 so as to hold articulation ball 910 within socket 920 of handle 10A.

If desired, and looking now at FIG. 91, an insert 970 (e.g., a rubber insert) may be inserted between one or more of the ribs 975 within socket 920 of handle 10A to create interference between the articulation ball 910 and socket 920. The interference created between articulation ball 910 and socket 920 provides a friction lock to further maintain articulation ball 910 within socket 920 of handle 10A, which, in turn, will maintain distal articulating portion 25 of shaft 15 in a desired angle relative to the distal end of flexible portion 20.

Alternatively, and looking now at FIG. 91A, a rubber O-ring 972 may be inserted between one or more ribs 975 within socket 920 of handle 10A to create interference between articulation ball 910 and socket 920. During movement of socket 920 of handle 10A around articulation ball 910, O-ring is compressed between ribs 975 in socket 920 and retaining ring 966. As with the aforementioned insert 970 discussed above, the interference created between articulation ball 910 and socket 920 of handle 10A helps to maintain distal articulating portion 25 of shaft 15 in a desired angle relative to the distal end of flexible portion 20.

9.2 Rotatable Shaft Adapter Mechanism 525A

Looking now at FIGS. 88-92, shaft 15 is rotatably mounted to the distal end of handle 10A by a rotatable shaft adapter mechanism 525A which permits shaft (i.e., both flexible proximal portion 20 and distal articulating portion 25) to be selectively rotated relative to handle 10A.

More particularly, shaft 15 is rotatably mounted to the distal end of handle 10A (near the distalmost end of articulation ball 910 of handle 10A) and can be selectively rotated using rotatable shaft adapter mechanism 525A. Rotatable shaft adapter mechanism 525A is similar to the rotatable shaft adapter mechanism 525 of FIGS. 56-58 and 58A-58F in that the proximal end of shaft 15 (i.e., the proximal end of flexible proximal portion 20) is rotatably mounted to the distal end of the handle, however, in this form of the invention, the proximal end of shaft 15 is rotatably mounted within a lumen 979 (FIG. 91) formed in the distal end of articulation ball 910 of handle 10A (e.g., with the aforementioned flange 530 (FIG. 58) on rigid tube 60 sitting on the proximal side of lumen 979). If desired, at least one groove 980 (FIG. 91) may be formed in lumen 979 of articulation ball 910 of handle 10A for receiving projections on the proximal end of rigid tube 60 of shaft 15, whereby to guide the proximal end of rigid tube 60 of shaft 15 through lumen 979 in order to position flange 530 of rigid tube on the proximal side of lumen 979.

Furthermore, rotatable shaft adapter mechanism 525A can be operated in a manner similar to the manner in which rotatable shaft adapter mechanism 525 is operated to unlock shaft 15 from handle 10A (i.e., by moving shaft rotation knob 545A distally against the power of a spring (i.e., spring 570 of FIG. 58) in order to “unlock” shaft 15, and then rotating shaft rotation knob 545A to rotate shaft 15 relative to handle 10A. After the user has rotated shaft 15 as desired, shaft adapter mechanism 525A is released and automatically moves proximally (i.e., under the power of spring 570) so as to “lock” shaft 15 against further rotation.

In this form of the invention, shaft rotation knob 545A of rotatable shaft adapter mechanism 525A may be provided with a raised feature 985. Raised featured 985 is formed on the outer surface of shaft rotation knob 545A and provides tactile and visible feedback relating to the position of shaft 15 (and thus end effector 30) relative to handle 10A (e.g., when raised feature 985 is disposed on the top of shaft rotation knob 545A, a user will know that shaft 15 is in a “neutral” (i.e., non-rotated) position relative to handle). If desired, raised feature 985 may be a different color than the remainder of shaft rotation knob 545A so as to make it easier for a user to see the position of the raised feature during operation of the device.

9.3 Gross Articulation Mechanism 1000 for Articulating Intermediate Articulating Portion 800

As discussed above, in one preferred form of the present invention, gross articulation control assembly 835 of handle 10 is used to selectively articulate flex spine 810 of intermediate articulating portion 800. As shown in FIGS. 81-87, gross articulation control assembly 835 generally comprises a spindle housing 840 fixedly mounted within internal cavity 280 of handle 10, a spindle 845 configured to be selectively rotated within spindle housing 840, and a knob 850 configured to be engaged by a user (FIG. 87). However, rotating knob 850 of gross articulation control assembly 835 to articulate flex spine 810 of intermediate articulating portion 800 typically requires the use of two hands (i.e., one hand to grip handle 10, and the other hand to rotate knob 850). Thus, it has been recognized that it may be desirable to provide a handle which permits single-handed articulation of flex spine 810 of intermediate articulating portion 800.

To this end, and looking now at FIGS. 88, 89 and 93, a gross articulation control assembly 1000 having a thumb slider mechanism 1005 is provided in order to enable flex spine 810 of intermediate articulating portion 800 to be articulated with a single hand of a user.

In this form of the invention, thumb slider mechanism 1005 generally comprises a thumb slider 1010 and a slider base 1015, with thumb slider 1010 and slider base 1015 being slidably disposed within a slot 1020 formed in the top of handle 10A. As will be discussed in further detail below, the proximal end of gross articulation cable 805 is mounted to slider base 1015 so that proximal movement of thumb slider 1010 will move gross articulation cable 805 proximally, whereby to selectively articulate flex spine 810 of intermediate articulating portion 800 of shaft 15 from a straight configuration to an articulated configuration (relative to flexible proximal portion 20 of shaft 15), and distal movement of thumb slider 1010 will cause the tension on the proximal end of gross articulation cable 805 to be relaxed, which will permit gross articulation cable 805 to move distally, whereby to enable flex spine 810 of intermediate articulating portion 800 of shaft 15 to return to its straight, non-articulated configuration.

More particularly, the proximal end of gross articulation cable 805 exits the proximal end of shaft 15, passes through an opening (not shown) in adjuster plate 935, and is mounted within a groove 1025 formed in slider base 1015 (FIG. 90).

If desired, a force-reducing spindle 1030 may be provided to reduce the amount of force which needs to be applied to articulation cable 805 in order to articulate flex spine 810 of intermediate articulating portion 800. Force-reducing spindle 1030 is preferably mounted to crimp plate 905 with a spacer 1035 and a pivot pin 1040. In this form of the invention, gross articulation cable 805 is passed around spindle 1030 before gross articulation cable 805 is attached to slider base 1015.

Preferably, thumb slider 1010 is spring-mounted to slider base 1015 so as to enable thumb slider mechanism 1005 to be selectively locked and unlocked from handle 10A so that intermediate articulating portion 800 can be maintained in a desired orientation, as will be discussed in further detail below.

More particularly, thumb slider 1010 comprises a top portion 1045 for engagement by a user's thumb and a bottom portion 1050. Bottom portion 1050 of thumb slider 1010 comprises two hollow posts 1055 which extend down towards top surface 1060 of slider base 1015, and a platform 1065 comprising a plurality of teeth 1070. An inner wall surface 1075 (FIG. 93) located beneath slot 1020 of handle 10A comprises a plurality of teeth 1080 which are configured to mate with the plurality of teeth 1070 on platform 1065 to lock platform 1065 (and hence thumb slider 1010) in position relative to slot 1020, as will be discussed in further detail below.

More particularly, a pair of springs 1085 extend upward from top surface 1060 of slider base 1015 into hollow posts 1055 for biasing platform 1065 of thumb slider 1010 “upward” into engagement with the plurality of teeth 1080 on inner wall surface 1075 of handle 10A. As a result of this construction, when thumb slider 1010 is in its resting state, the plurality of teeth 1070 formed on platform 1065 engage the plurality of teeth 1080 formed on inner wall surface 1075 of handle 10A, whereby to lock thumb slider 1010 in position relative to slot 1020 (and hence lock flex spine 810 of intermediate articulating portion 800 against further articulation).

When a user desires to articulate flex spine 810 of intermediate articulating portion 800, the user moves thumb slider 1010 “downward” against the power of springs 1085 (i.e., by pressing down on top portion 1045 of thumb slider 1010), whereby to move the plurality of teeth 1070 on platform 1065 out of engagement with the plurality of teeth 1080 on inner wall surface 1075 of handle 10A, thereby allowing thumb slider 1010 to be moved relative to slot 1020, as desired. While holding thumb slider 1010 “downward”, the user can then move thumb slider 1010 proximally, whereby to pull gross articulation cable 805 proximally, whereby to selectively articulate flex spine 810 of intermediate articulating portion 800 of shaft 15 from a straight configuration to an articulated configuration (relative to flexible proximal portion 20 of shaft 15). After the user has articulated intermediate articulating portion 800 to the desired angle, the user can release its thumb from thumb slider 1010, which permits the plurality of teeth 1070 on platform 1065 to be moved upward under the power of springs 1085 until the plurality of teeth 1070 engage the plurality of teeth 1080 on inner wall surface 1075 of handle 10A, thereby locking intermediate articulating portion 800 at its desired angle (i.e., degree of articulation) relative to the distal end of flexible proximal portion 20 of shaft 15. Thumb slider 1010 can thereafter be depressed to move thumb slider 1010, and released to lock thumb slider 1010, relative to handle 10A, as desired, in order to achieve the desired angle of articulation. In an exemplary use of this form of novel medical instrument 5 in a minimally-invasive procedure, the profile of end effector 30 is first reduced (e.g., where end effector 30 comprises a grasper, the jaws of the grasper are closed); shaft 15 is straightened; handle 10 is longitudinally advanced so as to longitudinally advance the distal end of medical instrument 5 through a portal and into the body (e.g., along a tortuous path); handle 10A is longitudinally advanced and/or rotated, and/or distal articulating portion 25 of shaft 15 is articulated, and/or intermediate articulating portion 800 is articulated, and/or end effector 30 is rotated so that end effector 30 appropriately addresses the target tissue at the internal site; end effector 30 is used to perform the desired procedure (e.g., where end effector 30 comprises a surgical grasper, the jaws of the grasper are opened and/or closed to grasp tissue and/or perform a surgical procedure) at the internal site; and the distal end of medical instrument 5 is withdrawn from the body, e.g., handle 10A is longitudinally withdrawn through the portal (during which the handle may also be rotated, and/or distal articulating portion 25 of shaft 15 is straightened (i.e., moved so as to assume its non-articulated configuration), and/or flex spine 810 of intermediate articulating portion 800 is straightened (i.e., moved so as to assume its non-articulated configuration) and/or end effector 30 is rotated and/or actuated (e.g., if necessary to reduce the profile of end effector 30), so that the end effector may be withdrawn from the body.

It will be appreciated by those skilled in the art that, if desired, the medical instrument may be modified so as to provide less (or more) than the seven aforementioned motions, e.g., the roticulation function may be eliminated, an additional rotational function such as selective rotation of shaft 15 may be added, etc.

9.4 Modifications to Distal Articulating Portion 25

In the preceding embodiments of the present invention, distal articulating portion 25 generally comprises a distal articulation link assembly 70, a proximal articulation link assembly 75 and a flex spine 80 extending between distal articulation link assembly 70 and proximal articulation link assembly 75. As shown in FIG. 5 flex spine 80 generally comprises a flexible body 140 having a distal end 141 and a proximal end 142. A plurality of axially-aligned openings 145, and a central bore 150, extend between distal end 141 and proximal end 142. Openings 145 are sized to each receive an articulation cable 220 and central bore 150 is sized to receive short laser-cut hypotube 115 (FIG. 7) of distal articulation link assembly 70. Proximal end 142 of flex spine 80 comprises proximal seats 155 for seating the aforementioned distally-extending fingers 90 (FIG. 6) of proximal articulation link assembly 75, and distal end 141 of flex spine 80 comprises distal seats 160 for receiving the aforementioned proximally-extending fingers 137 (FIG. 7) of distal articulation link assembly 70. It will be appreciated that when flex spine 80 is mounted in this fashion, flex spine 80 is fixed against rotation relative to either distal articulation link assembly 70 or proximal articulation link assembly 75.

However, it is noted that articulation cables 220 could “roll out” of openings 145 of flex spine 80 during articulation of distal articulating portion 25. Therefore, in some circumstances, it may be desirable to remove flex spine 80 and replace flex spine 80 with a washer 1105 in order to prevent “roll out” of one or more of articulations cables 220 during articulation of distal articulating portion 25. In this form of the invention, washer 1105 is provided with four openings 145A for receiving the four articulation cables 220 and a central bore 150A for receiving short laser-cut hypotube 115 of distal articulation link assembly 70.

9.5 Alternative End Effector

As discussed above, in a preferred form of the present invention, end effector 30 comprises a surgical grasper having two opposed jaws 216, 217 (FIG. 8). In this form of the invention, end effector 30 comprises a grasper having two opposed jaws 216, 217 which are pivotally mounted to end effector mount 210 via a pin 217A which passes through holes 217B in jaws 216, 217 and through holes 217C in end effector mount 210. A clevis 218 is mounted to jaws 216, 217 via a pin 218A disposed in slots 218B formed in the proximal portions of jaws 216, 217 such that reciprocal movement of pull wire 230 mounted to clevis 218 will cause the opposing jaws 216, 217 of the grasper to open and close relative to one another.

If desired, a “wave” washer 1110 (FIG. 95) may be provided to bias pull wire 230 distally, which in turn, will bias opposed jaws 216, 217 in their open configuration.

Alternatively, and/or additionally, and looking now at FIG. 96, if desired, a compression spring 1115 may be provided in order to bias clevis 218 distally (and hence, to bias pull wire 230 mounted to clevis 218 distally), whereby to bias opposed jaws 216, 217 into their open configuration.

MODIFICATIONS OF THE PREFERRED EMBODIMENTS

It should be understood that many additional changes in the details, materials, steps and arrangements of parts, which have been herein described and illustrated in order to explain the nature of the present invention, may be made by those skilled in the art while still remaining within the principles and scope of the invention. 

What is claimed is:
 1. Apparatus for performing a minimally-invasive procedure, the apparatus comprising: a shaft having a distal end, a proximal end and a longitudinal axis extending between the distal end and the proximal end, wherein the shaft comprises a flexible portion and an articulating portion, wherein the flexible portion extends distally from the handle assembly and the articulating portion extends distally from the flexible portion, and further wherein the articulating portion is configured to articulate relative to the flexible portion; a handle assembly attached to the proximal end of the shaft; and an end effector attached to the distal end of the shaft; wherein a plurality of articulation cables extends from the handle assembly to the articulating portion, such that when tension is applied to at least one of the plurality of articulation cables, the articulating portion bends relative to the flexible portion of the shaft; wherein the plurality of articulation cables are mounted to the handle assembly such that moving the handle assembly to angle the handle assembly relative to the longitudinal axis of the shaft applies tension to at least one of the plurality of articulation cables, whereby to articulate the articulating portion of the shaft relative to the flexible portion of the shaft.
 2. The apparatus of claim 1 wherein the plurality of articulation cables each comprise a distal end and a proximal end, wherein the handle assembly comprises an articulation cable plate for receiving the proximal ends of the plurality of articulation cables, and further wherein the articulation cable plate is fixed to the handle assembly such that when the handle assembly moves relative to the longitudinal axis of the shaft, tension is applied to at least one of the plurality of articulation cables.
 3. The apparatus of claim 2 wherein the handle assembly comprises a socket and the proximal end of the shaft comprises an articulation ball, and further wherein the socket is configured to rotate around the articulation ball to angle the handle assembly relative to the longitudinal axis of the shaft.
 4. The apparatus of claim 3 wherein the articulation cable plate is disposed proximal to the socket of the handle assembly.
 5. The apparatus of claim 1 wherein moving the handle assembly in a first direction causes articulation of the articulating portion towards the first direction.
 6. The apparatus of claim 3 further comprising a retaining ring for holding the articulation ball within the socket.
 7. The apparatus of claim 6 further comprising a friction lock for maintaining the articulation ball within the socket so as to maintain the articulating portion in a desired angle relative to the flexible portion.
 8. The apparatus of claim 1 wherein the shaft further comprises a gross articulating portion, wherein the gross articulating portion is disposed between the flexible portion and the articulating portion.
 9. The apparatus of claim 8 wherein a gross articulation cable extends from the handle assembly to the gross articulating portion, such that when tension is applied to the gross articulation cable, the gross articulating portion articulates.
 10. The apparatus of claim 9 wherein the handle assembly comprises a thumb slider mechanism for tensioning the gross articulation cable.
 11. Apparatus according to claim 8 wherein the articulating portion comprises a first flexible spine and the gross articulating portion comprises a second flexible spine.
 12. Apparatus according to claim 1 wherein each of the plurality of articulation cables have an articulation cable housing disposed about each of the plurality of articulation cables, such that when the articulating portion bends, the articulation cable housings provide a counterforce to the articulating portion.
 13. Apparatus according to claim 1 wherein a rotatable element extends from the handle to the end effector, such that when the rotatable element is rotated, the end effector rotates.
 14. Apparatus according to claim 1 wherein an actuation element extends from the handle to the end effector, such that when the actuation element is moved, the end effector is actuated.
 15. Apparatus according to claim 11 wherein the flexible portion of the shaft comprises an outer coil secured to the second flexible spine.
 16. Apparatus according to claim 1 further comprising a rigid tube configured to rotate relative to the handle, such that rotation of the rigid tube causes rotation of the shaft relative to the handle.
 17. Apparatus according to claim 13 wherein the rotatable element comprises a hollow tubular structure extending distally from the handle.
 18. Apparatus according to claim 17 wherein the rotatable element further comprises a laser-cut hypotube secured to the hollow tubular structure, such that when the hollow tubular structure is rotated, the laser-cut hypotube is also rotated.
 19. Apparatus according to claim 14 wherein the actuation element comprises a pull wire.
 20. Apparatus according to claim 1 wherein the end effector comprises one from the group consisting of: graspers, injection needles, scissors, hot snares, monopolar probes, hemostasis clips, bipolar forceps, suction tubes, single-fire or multi-fire closure devices such as staplers and tackers, dissector forceps, retrieval baskets, monopolar scissors, light sources and cameras.
 21. Apparatus according to claim 8 wherein the articulating portion and the gross articulating portion articulate independently of one another.
 22. A method for performing a minimally-invasive procedure, the method comprising: providing apparatus for performing the minimally-invasive procedure, the apparatus comprising: a shaft having a distal end, a proximal end and a longitudinal axis extending between the distal end and the proximal end, wherein the shaft comprises a flexible portion and an articulating portion, wherein the flexible portion extends distally from the handle assembly and the articulating portion extends distally from the flexible portion, and further wherein the articulating portion is configured to articulate relative to the flexible portion; a handle assembly attached to the proximal end of the shaft; and an end effector attached to the distal end of the shaft; wherein a plurality of articulation cables extends from the handle assembly to the articulating portion, such that when tension is applied to at least one of the plurality of articulation cables, the articulating portion bends relative to the flexible portion of the shaft; wherein the plurality of articulation cables are mounted to the handle assembly such that moving the handle assembly to angle the handle assembly relative to the longitudinal axis of the shaft applies tension to at least one of the plurality of articulation cables, whereby to articulate the articulating portion of the shaft relative to the flexible portion of the shaft; and using the apparatus to perform the minimally-invasive procedure. 